Absorbent garments with microporous films having zoned breathability

ABSTRACT

Breathable microporous films are provided having controlled regional breathability with thick high WVTR regions and thinner low WVTR regions. The zoned breathable microporous films can be made by selectively applying heat and pressure to the microporous film such as by feeding a microporous film through a pair of heated nip rollers with one of the rolls having a raised surface area.

FIELD OF THE INVENTION

The present invention relates to absorbent garments incorporatingbreathable microporous films. More particularly, the present inventionrelates to absorbent garments incorporating breathable microporous filmshaving zoned breathability and methods of making the same.

BACKGROUND OF THE INVENTION

Various types of garments are presently available for absorbing humandischarge. Examples of these garments include baby diapers, femininecare products, incontinence garments and the like. Generally speaking,the basic structure of this class of garments requires a liquid perviousbody-side liner, an absorbent pad containing one or more layers forreceiving and absorbing the discharge, and a liquid impervious backingmember for containing the discharge.

While some of these absorbent garments perform satisfactorily for theirintended purpose, there remains the need to provide a more discreteabsorbent garment that possesses improved comfort characteristics.

Heretofore, some absorbent garments for absorbing and containing humandischarge have typically been bulky and somewhat uncomfortable. Forexample, such absorbent garments may comprise flat sheets folded up intoa diaper-like configuration which are bulky, particularly in the crotchportion. Obviously, this style of absorbent garment is uncomfortable towear, especially if the wearer is an active adult. In addition, theabsorbent garments include a film material that serves as liquidimpervious outer cover. However, such film material lacks breathability,causing the absorbent garments to be hot and uncomfortable. The skinbecomes overly hydrated by the aqueous liquids (for example,perspiration) trapped against the skin by the non-breathable film,resulting in skin occlusion.

Thus, it becomes apparent that a need exists for an absorbent garmentthat improves the absorbent characteristics and the containmentcharacteristics of the absorbent garment while still being comfortableto wear as well as promoting skin wellness and skin dryness.

Microporous films are “breathable” barriers in the sense that the filmacts as a barrier to liquids and particulate matter but allows watervapor and air to pass therethrough. In addition, by achieving andmaintaining high breathability it is possible to provide an article thatis more comfortable to wear since the migration of water vapor throughthe fabric helps reduce and/or limit discomfort resulting from excessmoisture trapped against the skin. Thus, such an article can potentiallycontribute to an overall improved skin wellness.

Accordingly, microporous films have become an important article ofcommerce, finding a wide variety of applications. For example,microporous films have been used as backing members or as part of outercovers for personal care products such as diapers, training pants,incontinence garments, feminine hygiene products and the like. Inaddition, microporous films have likewise found use in protectiveapparel and infection control products such as surgical gowns, surgicaldrapes, protective workwear, wound dressings and bandages. Oftenmicroporous films are utilized as a multilayer laminate. The films canprovide the desired barrier properties to the article while othermaterials laminated thereto can provide additional characteristics suchas strength, abrasion resistance and/or good hand. For example, fibrouswebs such as nonwoven fabrics allow the laminate to retain itsbreathability and can provide additional strength as well as an articlehaving a cloth-like feel. Thus, microporous film laminates can be usedin a variety of applications including, for example, those describedabove.

Although the breathability provided by microporous films and/orlaminates thereof is advantageous in many articles, there exist somesituations where high breathability can be undesirable. For example, inpersonal care articles such as diapers or incontinence garments thebreathable barrier and absorbent core generally work together to retainbodily fluids (aqueous liquids) discharged into the garment. However,when aqueous liquid is retained within the absorbent core significantlyhigher levels of water vapor begin to pass through the breathablebarrier. The increased levels of water vapor passing through the outercover can form condensate on the outer portion of the garment. Thecondensate is simply water but can be perceived by the wearer asleakage. In addition, the condensate can create a damp uncomfortablefeel to the outer portion of the garment which is unpleasant for thosehandling the article. It is believed that the skin wellness and/orimproved comfort benefits of breathable outer covers are not achieved atareas directly adjacent the portion of the absorbent core retainingconsiderable amounts of liquid (e.g. typically those areas of thecentral or crotch region of the garment). Providing a breathable barrierwhich has less or limited breathability in such regions, while providinggood breathability in the remaining regions, would provide a garmentwith excellent wearer comfort yet which limits the potential for outercover dampness and odors. Thus, a breathable barrier that provideseither zoned or controlled regional breathability is highly desirable.

Therefore, there exists a need for a breathable microporous film havingregions with varied levels of breathability. In addition, there exists aneed for such films which retain the desired barrier properties andwhich are capable of lamination to additional materials. Further, thereexists a need for methods of making such films and in particular methodsof reliably obtaining the desired levels of breathability in distinctregions of a film.

Thus, it becomes apparent that a need exists for a breathable absorbentgarment that exhibits desired absorbency and containment characteristicsof the garments while improving comfort during use.

SUMMARY OF THE INVENTION

The present invention provides an improved breathable absorbent garmenthaving improved comfort characteristics. The breathable absorbentgarment of the invention provides an absorbent pad disposed between abreathable backing member and a body-side liner. The breathableabsorbent garment may also include an elasticized design that alsofacilitates the formation of the crotch section, as well as andeffective seal between the garment and the wearer, whereby the garmentis comfortable to wear.

The aforesaid needs are fulfilled and the problems experienced by thoseskilled in the art overcome by the film of present invention which, inone aspect, comprises a first microporous region having a thickness lessthan 100μ and a WVTR (also referred to as porosity) of at least 800g/m²/24 hours and a second region having a WVTR less than that of thefirst region wherein the WVTR of the second region is at least 15% lessthan the WVTR of the first region. The film has a hydrohead of at leastabout 50 mbar. The second region desirably has minimum dimensions of 5cm by 5 cm and still more desirably comprises from about 5% to about 75%of the area of said film. In a further aspect, the first region can havea WVTR in excess of about 2500 g/m²/24 hours and the second region aWVTR less than about 1500 g/m²/24 hours. Additionally and/oralternatively, the second region can have a WVTR at least about 50% lessthan the WVTR of the first region. Further, the film can comprise athird region having a WVTR intermediate to that of the first and secondregions. Still further, the film can comprise primarily of athermoplastic polymer and in a further aspect, can comprise at leastabout 40% by weight filler and a thermoplastic polymer. One aspect ofthe present invention is to provide a microporous film having zonedbreathability. Such a film reduces, and in some cases, preventscondensation on the outer surface of the breathable absorbent garment.

Further aspects of the present invention will appear in the descriptionhereinafter.

Definitions

As used herein the term “nonwoven” fabric or web means a web having astructure of individual fibers or threads which are interlaid, but notin an identifiable manner as in a knitted or woven fabric. Nonwovenfabrics or webs have been formed by many processes such as for example,meltblowing processes, spunbonding processes, hydroentangling, air-laidand bonded carded web processes.

As used herein the term “spunbond fibers” refers to small diameterfibers of molecularly oriented polymeric material. Spunbond fibers maybe formed by extruding molten thermoplastic material as filaments from aplurality of fine, usually circular capillaries of a spinneret with thediameter of the extruded filaments then being rapidly reduced as by, forexample, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No.3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki etal., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No.3,502,763 to Hartman, U.S. Pat. No. 3,542,615 to Dobo et al, U.S. Pat.No. 5,382,400 to Pike et al.,and U.S. Pat. No. 5,759,926 to Pike et al.Spunbond fibers are generally not tacky when they are deposited onto acollecting surface and are generally continuous.

As used herein the term “meltblown fibers” means fibers of polymericmaterial which are generally formed by extruding a molten thermoplasticmaterial through a plurality of fine, usually circular, die capillariesas molten threads or filaments into converging high velocity, usuallyhot, gas (e.g. air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter. Thereafter, themeltblown fibers can be carried by the high velocity gas stream and aredeposited on a collecting surface to form a web of randomly dispersedmeltblown fibers. Such a process is disclosed, for example, in U.S. Pat.No. 3,849,241 to Butin et al. Meltblown fibers may be continuous ordiscontinuous, are generally smaller than 10 microns in averagediameter, and are generally tacky when deposited onto a collectingsurface.

As used herein “multilayer nonwoven laminate” means a laminate of two ormore nonwoven layers such as, for example, wherein some of the layersare spunbond and some meltblown such as aspunbond/meltblown/spunbond(SMS) laminate. Examples of multilayernonwoven laminates are disclosed in U.S. Pat. No. 4,041,203 to Brock etal., U.S. Pat. No. 5,178,931 to Perkins et al. and U.S. Pat. No.5,188,885 to Timmons et al. Such a laminate may be made by sequentiallydepositing onto a moving forming belt first a spunbond fabric layer,then a meltblown fabric layer and last another spunbond layer and thenbonding the laminate such as by thermal point bonding as describedbelow.

Alternatively, the fabric layers may be made individually, collected inrolls, and combined in a separate bonding step.

As used herein, the term “machine direction” or MD means the length of afabric in the direction in which it is produced. The term “cross machinedirection” or CD means the width of fabric, i.e. a direction generallyperpendicular to the MD.

As used herein the term “polymer” generally includes but is not limitedto, homopolymers, copolymers, such as for example, block, graft, randomand alternating copolymers, terpolymers, etc. and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” includes all possible spatial configurationsof the molecule. These configurations include, but are not limited toisotactic, syndiotactic and random symmetries.

As used herein, “ultrasonic bonding” means a process performed, forexample, by passing the fabric between a sonic horn and anvil roll asillustrated in U.S. Pat. No. 4,374,888 to Bornslaeger.

As used herein “point bonding” means bonding one or more layers offabric at numerous small, discrete bond points. For example, thermalpoint bonding generally involves passing one or more layers to be bondedbetween heated rolls such as, for example an engraved pattern roll and asmooth calender roll. The engraved roll is patterned in some way so thatthe entire fabric is not bonded over its entire surface, and the anvilroll is usually flat. As a result, various patterns for engraved rollshave been developed for functional as well as aesthetic reasons. Oneexample of a pattern has points and is the Hansen Pennings or “H&P”pattern with about a 30% bond area when new and with about 200bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen et al.

As used herein, the term “barrier” means a film, laminate or otherfabric which is relatively impervious to the transmission of liquids andwhich has a hydrohead of at least about 50 mbar. Hydrohead as usedherein refers to a measure of the liquid barrier properties of a fabricmeasured in millibars (mbar) as described herein below. However, itshould be noted that in many applications of barrier fabrics, it may bedesirable that they have a hydrohead value greater than about 80 mbar,150 mbar or even 200 mbar.

As used herein, the term “breathability” refers to the water vaportransmission rate (WVTR) of an area of fabric which is measured in gramsof water per square meter per day (g/m²/24 hours). The WVTR of a fabricis the water vapor transmission rate which, in one aspect, gives anindication of how comfortable a fabric would be to wear. WVTR can bemeasured as indicated below and the results are reported in grams/squaremeter/day.

As used herein the term “backsheet” refers to the aqueous liquidimpervious protective layer on the garment side of a personal careproduct which prevents bodily exudates from escaping from the product.

As used herein the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which additives have beenadded. As used herein the term “multicomponent fibers” refers to fiberswhich have been formed from at least two polymers extruded from separateextruders but spun together to form one fiber. Multicomponent fibers arealso sometimes referred to as conjugate or bicomponent fibers. Thepolymers of a multicomponent fiber are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thefiber and extend continuously along the length of the fiber. Theconfiguration of such a fiber may be, for example, a sheath/corearrangement wherein one polymer is surrounded by another or may be aside by side arrangement, a pie arrangement or an“islands-in-the-sea”type arrangement. Multicomponent fibers are taughtin U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 4,795,668 toKrueger et al. and U.S. Pat. No. 5,336,552 to Strack et al. Conjugatefibers and methods of making them are also taught in U.S. Pat. No.5,382,400 to Pike et al. and may be used to produce crimp in the fibersby using the differential crystallization properties of the two (ormore) polymers. The fibers may also have various shapes such as thosedescribed in U.S. Pat. Nos. 5,277,976 to Hogle et al., U.S. Pat. No.5,466,410 to Hills and 5,069,970 and 5,057,368 to Largman et al.

As used herein the term “blend” means a mixture of two or more polymerswhile the term “alloy” means a sub-class of blends wherein thecomponents are immiscible but have been compatibilized.

As used herein the term “biconstituent fibers” or “multiconstituent”refers to fibers which have been formed from at least two polymersextruded from the same extruder as a blend. The term “blend” is definedabove. Biconstituent fibers do not have the various polymer componentsarranged in relatively constantly positioned distinct zones across thecross-sectional area of the fiber and the various polymers are usuallynot continuous along the entire length of the fiber, instead usuallyforming fibrils or protofibrils which start and end at random.Bicomponent and biconstituent fibers are discussed in U.S. Pat. No.5,294,482 to Gessner and in the textbook Polymer Blends and Compositesby John A. Manson and Leslie H. Sperling, copyright 1976 by PlenumPress, a division of Plenum Publishing Corporation of New York, ISBN0-306-30831-2, at pages 273 through 277.

As used herein, the term “scrim” means a lightweight fabric used as abacking material. Scrims are often used as the base fabric for coated orlaminated products.

As used herein, the term “garment” means the same as the term “personalcare product”.

As used herein, the term “infection control product” means medicallyoriented items such as surgical gowns and drapes, face masks, headcoverings like bouffant caps, surgical caps and hoods, footwear likeshoe coverings, boot covers and slippers, wound dressings, bandages,sterilization wraps, wipers, garments like lab coats, coveralls, apronsand jackets, patient bedding, stretcher and bassinet sheets and thelike.

As used herein, the term “personal care product” means personal hygieneoriented items such as diapers, training pants, absorbent underpants,adult incontinence products, feminine hygiene products, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a specific embodiment of the inventionwith a portion of the liquid impervious backing member removed to exposethe interior structure of the embodiment;

FIG. 2 is a plan view of the specific embodiment of FIG. 1 in anextended condition with the liquid pervious liner facing the viewer, anda portion of the liquid pervious liner and a portion of the absorbentpad removed;

FIG. 3 is a cross-sectional view of the specific embodiment of FIG. 2taken along section line 3—3 of FIG. 2;

FIG. 3a is a cross-sectional view of an embodiment of FIG. 2 taken alongsection line 3—3 of FIG. 2;

FIG. 4a is a perspective view of a specific embodiment of the inventionwith a portion of the liquid impervious backing member removed to exposethe interior structure of the embodiment;

FIG. 4b is a plan view of the specific embodiment of FIG. 4a in anextended condition with the liquid pervious liner facing the viewer, anda portion of the liquid pervious liner and a portion of the absorbentpad removed;

FIG. 4c is a cross-sectional view of the specific embodiment of FIG. 4btaken along section line 3—3 of FIG. 4b;

FIG. 5 is a schematic representation of an exemplary nip roll assemblysuitable for use in practicing the present invention and a zone treatedfilm made therefrom;

FIG. 6 is a cross-section of a treated microporous film shown in FIG. 5take at A—A′;

FIG. 7 is a cross-section representation of an exemplary patterned rollsuitable for use in practicing the present invention;

FIG. 8 is a schematic representation of an exemplary nip roll assemblysuitable for practicing the present invention and a zone treated filmmade therefrom;

FIG. 9 is a schematic representation of an exemplary nip roll assemblysuitable for use in practicing the present invention and a zone treatedfilm made therefrom;

FIG. 10 is a schematic representation of an exemplary nip roll assemblysuitable for use in practicing the present invention and a zone treatedfilm made therefrom;

FIG. 11 is a cross-section representation of an exemplary patterned rollsuitable for use in practicing the present invention;

FIG. 12 is a cross-section representation of an exemplary patterned rollsuitable for use in practicing the present invention;

FIG. 13 is a photomicrograph of an untreated region of a microporousbreathable film;

FIG. 14 is a photomicrograph of an treated region of the samemicroporous breathable film shown in FIG. 13;

FIG. 15a is a schematic representation of an exemplary adhesiveapplicator assembly suitable for use in practicing the present inventionand a zone treated film made therefrom;

FIG. 15b is a schematic representation of an exemplary adhesiveapplicator assembly suitable for use in practicing the present inventionand a zone treated film made therefrom;

FIG. 16a is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 16b is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 17a is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 17b is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 18a is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 18b is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 19a is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 19b is a plan view of a zone treated microporous film suitable foruse in practicing the present invention;

FIG. 20 is a schematic representation of an adhesive application patternsuitable for use n practicing the present invention;

FIG. 21 is a schematic representation of an adhesive application patternsuitable for use in practicing the present invention;

FIG. 22 is a plan view of a zoned treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 23 is a plan view of a zoned treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 24 is a plan view of a zoned treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon

FIG. 25 is a plan view of a zoned treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 26 is a plan view of a treated microporous film having an openadhesive pattern with minimal effect on the WVTR of the film;

FIG. 27 is a plan view of a treated microporous film having an adhesivecoat layer with significant reduction of the WVTR of the film; and,

FIG. 28 is a plan view of a treated microporous film having an adhesivecoat layer with significant reduction of the WVTR of the film.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 through 3a, there is illustrated one specificembodiment of the invention generally designated as 20, which presentlyis considered to be the best mode of practicing the invention. Thebreathable absorbent garment 20 includes a liquid impervious/vaporpervious backing member 22 that is of generally rectangular shape. Theabsorbent garment 20 has a peripheral edge 24 which includes side edges26 and 28, a front edge 30 and a back edge 32. Throughout thespecification, the term “generally rectangular” is used by theapplicants. However, it is not intended that this term be limited toonly a rectangular shape. But, instead, this term can include geometricshapes that are rectangular, oval or racetrack patterns, hourglassconfigurations, bilobal shapes, and in general any shape where thelength is greater or less than the width.

The breathable absorbent garments 20 consists of the breathable backingmember 22, a substantially liquid pervious body-side liner 40, and anabsorbent pad 58 sandwiched between the backing member 22 and thebody-side liner 40. The backing member 22 and the body-side liner 40 aredesirably longer and wider than the absorbent pad 58, so that theperipheries of the backing member 22 and the body-side liner 40 formmargins which may be sealed together using ultrasonic bonds, thermalbonds, adhesives, or other suitable means. In this sealed area, the legelastics 96 and 108 may be incorporated between the backing member 22and the body-side liner 40. The absorbent pad 58 may be attached to thebacking member 22 and/or the body-side liner 40 using ultrasonic bonds,adhesives, or other suitable means. (See FIGS. 1, 2, and 3). In someembodiments, the breathable absorbent garments 20 also include an outermember 38. The outer member 38 is attached to the backing member 22using ultrasonic bonds, adhesives, or other suitable means.

The breathable absorbent garment 20 can be constructed by supplyingbody-side liner 40 and backing member 22 materials and sandwiching anindividual absorbent pad 58 between the backing member 22 and thebody-side liner 40. The side and end peripheries of the backing member22 and the body-side liner 40 outward of the absorbent pad 58 can bejoined with the crotch region 35, the front waist region 37, and theback waist region 39 and sealed together. The absorbent pad 58 mayoptionally be T-shaped, I-shaped, oval-shaped, hourglass-shaped,rectangular-shaped, or irregularly-shaped. In addition, the absorbentcore 58 may also include leg cutout, opposing indentations in thelongitudinal side 62 and 64 of the absorbent pad 58. Leg cutout mayimprove the fit of the garment 20 as the reduced bulk between thewearer's legs reduces or prevents gapping thereby preventing leaks aswell as improving comfort. The other materials used in the garment 20,including but not limited to the body-side liner 40, the backing member22, and the outer member 38 may also be shaped to include leg cutouts.However, in some embodiments, it may be desirable for the absorbent pad58 to be shaped to include leg cutouts, and not shape the othermaterials, including the body-side liner 40, the backing member 22, andthe outer member 38, to include leg cutouts.

The liquid impervious/vapor pervious backing member 22 has an exteriorsurface 34 that faces away from the wearer and an interior surface 36that faces toward the wearer. In construction of the breathableabsorbent garment 20, the backing member 22, acting as a barrier, shouldretard the movement of the liquid through the breathable absorbentgarment 20 by making the backing member 22 resistant to liquidpenetration normally encountered under wearing conditions whileremaining pervious to water vapor. The backing member 22 desirablycomprises a material that is formed or treated to be aqueous liquidimpervious. Alternatively, the backing member 22 may comprise a aqueousliquid pervious material and other suitable means (not shown), such as aaqueous liquid impervious/vapor pervious layer associated with theabsorbent pad 58 may be provided to impede aqueous liquid movement awayfrom the absorbent pad 58.

The backing member 22 may comprise a thin, liquid impervious/vaporpervious web or sheet of plastic film such as polyethylene,polypropylene, or polyolefin copolymers such as ethylene vinyl acetate,ethylene methylacrylate, ethylene ethyl acrylate, polyvinyl chloride,Nylon and similar material. Other acceptable materials include a singlespunbonded layer of the above types of materials, two layers ofspunbonded and meltblown materials or a three-layer material ofspunbonded- meltblown-spunbonded material. Suitable foam materials mayalso be used, as well as materials that are both aqueous liquidimpervious and vapor-pervious.

Alternately, the backing member 22 may comprise a nonwoven, fibrous webwhich has been suitably constructed and arranged to have low liquidperviousness. Still alternately, the backing member 22 may comprise alayered or laminated material, such as a thermally bonded plastic filmand nonwoven web composite. More preferred, the backing member 22 has awater vapor transmission rate of at least about 500 grams/m²/24 hoursmeasured by ASTM E96-92. One example of a suitable film is a 39.4 gramsper square meter microporous film produced by Mitsui and sold byConsolidated Thermoplastics (CT) under the tradename of ESPOIR®N-TAF-CT.

The term “liquid impervious” as used herein to describe a layer orlaminate means that aqueous liquid such as urine will not pass throughthe layer or laminate under ordinary use conditions in a directiongenerally perpendicular to the plane of the layer or laminate at thepoint of the aqueous liquid contact.

The backing member 22 is needed to prevent liquid strike through to theouter clothing when discharge occurs onto the absorbent pad 58 of thebreathable absorbent garment 20. The backing member 22 is located on theinside of the outer member 38 of the breathable absorbent garment 20 andtypically consists of an aqueous liquid impervious film such aspolyethylene. Use of only the film (without the outer member 38) may notbe durable enough to withstand extended periods of wear. The absorbentpad 58 may be associated with a backing member 22 which may or may notinclude elastic characteristics.

In another embodiment of the present invention, the breathable absorbentgarment 20 includes an aqueous liquid pervious body-side liner 40 and asubstantially aqueous liquid impervious breathable backing member 22superposed on the outer member 38. (See FIG. 3.) The absorbent pad 58 issandwiched between the backing member 22 and the body-side liner 40.(See FIGS. 1, 2, 3, and 3 a.) The backing member 22 and the body-sideliner 40 are desirably longer and wider than the absorbent pad 58. Thebody-side liner 40 is designed to be positioned toward the wearer and isreferred to as the body-facing surface 21 of the breathable absorbentgarment 20. Conversely, the backing member 22 is designed to bepositioned toward the outer member 38 and the outer clothing of thewearer and is referred to as the garment-facing surface 23 of thebreathable absorbent garment 20.

The outer member 38 is compliant and soft feeling to the wearer. Theouter member 38 may be any soft, flexible, porous sheet which is liquidpervious, permitting liquids to readily penetrate into its thickness, orimpervious, resistant to the penetration of liquids into its thickness.A suitable outer member 38 may be manufactured from a wide range ofmaterials, such as natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyester or polypropylene fibers) or from acombination of natural and synthetic fibers or reticulated foams andapertured plastic films.

There are a number of manufacturing techniques which may be used tomanufacture the outer member 38. Generally, the composition of thefibrous layer may be selected to achieve the desired properties, i.e.hand, aesthetics, tensile strength, cost, abrasion resistance, hookengagement, etc. It is understood that the bonding means used to attachthe fabric layer to the microporous film should not impair thebreathability of the microporous film. This concern is not as great inareas where reduced WVTR is desired.

For example, the outer member 38 may be woven or nonwoven web or sheetsuch as a spunbond, meltblown or bonded-carded web composed of syntheticpolymer filaments, such as polypropylene, polyethylene, polyesters orthe like, or a web of natural polymer filaments such as rayon or cotton.The bonded-carded web may be thermally bonded or sprayed with a binderby means well known to those skilled in the fabric art. Suitably, theouter member 38 is a nonwoven spunbond. Ideally, the outer member 38 isa spunbond polypropylene nonwoven with a wireweave bond pattern.Suitably, the spunbond material is available from Kimberly-ClarkCorporation, located in Roswell, GA. The outer member 38 has a weightfrom about 0.3 oz. per square yard (osy) to about 2.0 osy andalternatively about 0.6 osy. The outer member 38 of the absorbentgarment 20 maybe printed, colored or decoratively embossed. The outermember 38 has a pore size that readily allows the passage therethroughof air, sweat, perspiration, and water vapor due to the breathability ofthe material. The outer member 38 may be selectively embossed orperforated with discrete slits or holes extending therethrough.

The breathable absorbent garment 20 further includes a generallyrectangular liquid pervious body-side liner 40 that is of approximatelythe same dimension as liquid impervious backing member 22. Liquidpervious body-side liner 40 has a peripheral edge 42 comprising a frontedge 44, a back edge 46, and side edges 48 and 50. Liquid perviousbody-side liner 40 has an exterior surface 52 that faces away from thewearer and an interior surface 54 that faces towards the wearer.

The body-side liner 40 is formed of an aqueous liquid pervious materialso that aqueous liquid waste, and possibly semi-solid waste as well, canpass through to the absorbent pad 58 and be absorbed by the absorbentpad 58). A suitable body-side liner 40 may be comprised a nonwoven web,a spunbond, meltblown or bonded-carded web composed of synthetic polymerfilaments or fibers, such as polypropylene, polyethylene, polyesters orthe like, a perforated film, or a web or natural polymer filaments orfibers such as rayon or cotton. In addition, the body-side liner 40 maybe treated with a surfactant to aid in aqueous liquid transfer.Suitably, the body-side liner 40 is a nonwoven spunbond. Ideally, thebody-side liner 40 is a spunbond polypropylene nonwoven with a wireweavebond pattern. Suitably, the spunbond material is available fromKimberly-Clark Corporation, located in Roswell, Ga. The body-side liner40 has a weight from about 0.3 oz. per square yard (osy) to about 2.0osy and preferably about 0.5 osy. The body-side liner 40 of theabsorbent garment maybe printed, colored or decoratively embossed. Thebody-side liner 40 has a pore size that readily allows the passagetherethrough of air, sweat, perspiration due to the breathability of thematerial. The body-side liner 40 may be selectively embossed orperforated with discrete slits or holes extending therethrough.

The fabric is surface treated with a surfactant commercially availablefrom Union Carbide Chemicals and Plastics Company, Inc., of Danbury,Conn., U.S.A. under the trade designation TRITON X-102. As used herein,the term “fabric” refers to all of the woven, knitted and nonwovenfibrous webs. The term “nonwoven web” means a web of material that isformed without the aid of a textile weaving or knitting process.

The liquid impervious backing member 22 and liquid pervious body-sideliner 40 are joined near their respective peripheral edges 24 and 42 toform what can be considered to be a container, generally designated as74, that defines an interior volume. This interior volume contains theremaining structure of the breathable absorbent garment 20, whichcomprises an absorbent pad 58.

The liquid impervious backing member 22 and the liquid perviousbody-side liner 40 have essentially the same width and length. The widthof backing member 22 and the body-side liner 40 ranges between about 4inches (10.2 cm) and about 10 inches (25.4 cm) and, more preferablybetween about 5 inches (12.7 cm) and about 10 inches (25.4 cm) and about27 inches (68.6 cm). The length of backing member 22 and the body-sideliner 40 ranges between about 20 inches (50.8 cm) and about 30 inches(76.2 cm), more preferably between 21 inches (53.3 cm) and about 29inches (73.7 cm), and most preferably between about 23 inches (58.4 cm)and about 28 inches (71.1 cm). In the specific embodiment of theinvention as illustrated in FIGS. 1-4, the width of the backing member22 and body-side liner 40 is about 9 inches (22.9 cm), and the length isabout 27 inches ( 68.6 cm).

The absorbent pad 58 is of a generally rectangular shape and includes aperipheral edge 60 comprised of side edges 62 and 64, a front end edge66 and a back end edge 68. The absorbent pad 58 has an exterior surface70 that faces away from the wearer, and an interior surface 72 thatfaces towards the wearer.

The absorbent pad 58 comprises materials adapted to absorb and retainurine, menses, blood, or other body exudates. The absorbent pad 58 maycomprise various natural or synthetic absorbent materials, such ascellulose fibers, surfactant treated meltblown fibers, wood pulp fibers,regenerated cellulose or cotton fibers, a blend of pulp and other fiber,chemically stiffened cellulose fibers, or the like. One such material isa coform material which is composed of a mixture of cellulosic fibersand synthetic polymer fibers. The absorbent pad 58 may also includecompounds to increase its absorbency, such as 0-95 weight percent oforganic or inorganic high-absorbency materials, which are typicallycapable of absorbing at least about 15 and desirably more that 25 timestheir weight in water. Suitable high-absorbency materials are describedin U.S. Pat. Nos. 4,699,823 issued Oct. 13, 1987, to Kellenberger et at.and 5,147,343 issued Sep. 15, 1992 to Kellenberger, which areincorporated herein by reference. High absorbency materials areavailable from various commercial vendors, such as Dow Chemical Company,Hoechst Celanese Corporation, Stockhausen, Inc., and Allied Colloids,Inc. The absorbent pad 58 may also include tissue layers or acquisitionor distribution layers to help maintain the integrity of fibrousabsorbents, to facilitate liquid intake, and to transport liquid withinthe absorbent pad 58.

The breathable absorbent garment 20 may also include additionalcomponents to assist in the acquisition, distribution, and storage ofbody exudates. For example, the breathable absorbent garment 20 mayinclude a transport layer, such as described in U.S. Pat. No. 4,798,603issued Jan. 17, 1989, to Meyer et al., or a surge management layer, suchas described in U.S. Pat. No. 5,486,166 issued Jan. 23, 1996, to Bishopet al., U.S. Pat. No. 5,364,382 issued Nov. 15, 1994, to Latimer et al.,and European Patent No. 0 539 703, granted Mar. 5, 1997, which thepatents are incorporated herein by reference. Such layers are alsoreferred to as acquisition/distributionlayers and surge layers.

One suitable absorbent pad 58 is separately illustrated in FIG. 3a andcomprises an aqueous liquid storage layer 76 and anacquisition/distribution layer 78. The acquisition/distribution layer 78has two sections. The 1st section, the acquisition section (not shown),has a greater aqueous liquid capacity per unit area with 479 gsm fluffpulp, such as CR1654 supplied by Alliance U.S. in Coosa Pines, Ala., and260 gsm high absorbency material (herein also referred to as “SAP” or“SAM”). The acquisition section is centered in the area where urine willbe insulted by the user. The second section (not shown) has lowercapacity per unit area, 215 gsm fluff pulp and 117 gsm SAP.

The acquisition/distribution layer 78 is disposed on the aqueous liquidstorage layer 76 toward the body-facing surface 21 of the absorbent pad58 to help decelerate and diffuse surges of aqueous liquid that may beintroduced into the absorbent pad 58. The acquisition/distribution layer78 may comprise a through-air bonded carded web composed of a blend of40 percent 6 denier polyester fibers, commercially available fromHoechst Celanese Corporation, and 60 percent 3 denierpolypropylene/polyethylene sheath core bicomponent fibers, commerciallyavailable from the Chisso Corporation, with an overall basis weightranging of from about 50 gsm and about 120 gsm. Alternativeacquisition/distribution materials are described in U.S. Pat. No.5,192,606 issued Mar. 9, 1993, to D. Proxmire et al.; U.S. Pat. No.5,486,166 issued Jan. 23, 1996 to Ellis et al.; U.S. Pat. No. 5,490,846issued Feb. 13, 1996 to Ellis et al.; and U.S. Pat. No. 5,509,915 issuedApr. 23, 1996 to Hanson et al.; the disclosures of which are herebyincorporated by reference. The illustrated acquisition/distributionlayer 78 is rectangular with a length of about 305 mm. And a width ofabout 76 mm. The acquisition/distribution layer 78 can vary in shape andsize as disclosed for the absorbent pad 58 and the breathable absorbentgarment 20.

The pledget 140 (see FIGS. 4a, 4 b, and 4 c) is of a generallyrectangular shape and has a peripheral edge 142 with a front edge 144, aback edge 146, and side edges 148 and 150. Pledget 140 has an exteriorsurface 152 facing away from the wearer and an interior surface 154facing towards the wearer. The pledget 140 is dimensioned relative tothe absorbent pad 58 such that its width and length are each less thanthe width and length of the absorbent pad 58, respectively. In thisregard, the length of the pledget 140 is measured along the front andback edges 144 and 146 thereof and the width of the pledget 140 ismeasured along the side edges 148 and 150 thereof. The length of theabsorbent pad 58 is measured along the front end and back end edges 66and 68 and the width of the absorbent pad 58 is measured along the sideedges 62 and 64.

The pledget 140 is most preferably made from a blend of fiberscomprising about 15 to about 30 weight percent polypropylene orpolyethylene fibers and about 85 to about 70 weight percent wood pulpfluff fibers, and has a basis weight of about 100 to about 525 gsm. Inaddition, a superabsorbent is added in an amount of about 10 to about100 gsm. The pledget 140 may be formed on a tissue or a spunbondedcarrier sheet, or may be formed without a carrier sheet.

The pledget 140 of the specific embodiment has a width equal to about5.75 inches (14.6 cm) and a length equal to about 12 inches (30.5 cm).It is contemplated that the pledget 140 can have a width between about 3inches (7.6 cm) and about 8.5 inches (21.6 cm), and a length betweenabout 6 inches (15.2 cm) and about 14 inches (35.6 cm). The pledget 140has a dry thickness equal to about 2.63 mm to about 17.5 mm.

The pledget 140 is illustrated in the drawings to have a dry thicknessthat is approximately equal to the dry thickness of the absorbent pad58. However, it should be appreciated that the pledget 140 and absorbentpad 58 can be of different thicknesses. For example, the pledget 140 canbe from about one-half to about four time the thickness of the absorbentpad 58.

The pledget 140 can be positioned so as to be symmetrical about thecentral longitudinal and transverse axes A—A, B—B, respectively, of thebreathable absorbent garment 20. When in this position, the front andback edges 144 and 146 of pledget 140 are equi-distant from the frontand back edges 44 and 46 of the body-side liner 40, respectively, andthe side edges 148 and 150 of pledget 140 are equi-distant from the sideedges 48 and 50 of the body-side liner 40, respectively. Further, whenin this position, the absorbent pad 58 extends past the peripheral edgeof the pledget 140.

The pledget 140 can, however, as illustrated in FIGS. 4a and 4 b, bepositioned so that either the front or back edges 144 and 146 is no lessthan 2 inches (5.1 cm) from its respective front or back edges 44and 46of the body-side liner 40 while still being symmetrical about thecentral longitudinal axis A—A. In other words, the pledget 140 can beasymmetrical about the transverse axis B—B.

In other embodiments of the present invention, the breathable absorbentgarment 20 includes a single layer absorbent pad 58. The absorbent pad58 comprises materials adapted to absorb and retain urine, menses, bloodor other body excrement. The absorbent pad 58 may comprise variousnatural or synthetic absorbent materials, such as cellulose fibers,surfactant treated meltblown fibers, wood pulp fibers, regeneratedcellulose or cotton fibers, a blend of pulp and other fibers, or thelike. One such material is coform material which is composed of amixture of cellulosic fibers and synthetic polymer fibers. The absorbentpad 58 may also include compounds to increase its absorbency, such as0-95 weight percent of organic or inorganic high-absorbency materials,which are typically capable of absorbing at least about 15 and desirablymore than 25 times their weight in water. Suitable high-absorbencymaterials are described in U.S. Pat. Nos. 4,699,823 issued Oct. 13,1987, to Kellenberger et at.; and 5,147,343 issued Sep. 15, 1992, toKellenberger, which are incorporated herein by reference.High-absorbency materials are available from various commercial vendors,such as Dow Chemical Company, Hoechst Celanese Corporation, Stockhausen,Inc., and Allied Colloids, Inc.

One suitable absorbent pad 58 for the breathable absorbent garment 20 isseparately illustrated in FIG. 3a and comprises an aqueous liquidstorage layer 76. The aqueous liquid storage layer 76 comprises anair-laid mixture of about 470 gsm wood pulp fibers and about 305 gsmhigh-absorbency materials that is sandwiched or wrapped between 19 gsmcellulose tissues (wrap layers 80). The aqueous liquid storage layer 76is desirably embossed using a matched male/male embossing roll. Thetypical absorbent pad 58 is hourglass shaped with a length of betweenabout 17 inches (430 mm) and about 25 inches (635 mm) and a width ofbetween about 2.5 inches (64mm) and about 6 inches (152 mm). Theabsorbent pad 58 desirably has a thickness dimension of less than about20 mm, particularly less than about 10 mm.

The absorbent pad 58 can comprise a coform material composed of amixture of cellulosic fibers and synthetic polymer fibers. For example,the coform material may comprise an airlaid blend of cellulosic woodfibers and meltblown polyolefin fibers, such as polyethylene orpolypropylene fibers. Absorbent pad 58 can comprise only coform, acombination of superabsorbent materials and coform, coform with otherabsorbent or non-absorbent materials including anacquisition/distribution layer, or any combination thereof.

The coform material may comprise an airlaid blend of cellulosic woodfibers and meltblown polyolefin fibers, such as polyethylene orpolypropylene fibers, or may comprise an air-formed batt of cellulosicfibers (i.e., wood pulp fluff). Optionally, the absorbent pad 58 may betreated with a surfactant to aid in aqueous liquid acquisition when in adry environment. In particular embodiments of the invention, theabsorbent pad 58 has a bulk thickness of not more than about 40 mm whendry. The hydrophilic fibers and polymer strands may be provided in afiber-to-polymer ratio which is greater than 20:80, for example betweenabout 60:40 and about 98:2 and, desirably between about 80:20 and about90:10. In coform material containing super absorbent materials, thefiber/high absorbency material ratio is between about 90:10 to about50:50, and desirably between about 60:40 to about 65:35. High absorbencymaterials are discussed below.

Organic high-absorbency materials can include natural materials, such aspectin, guar gum and peat moss, as well as synthetic materials, such assynthetic hydrogel polymers. Such hydrogel polymers may include, forexample, carboxymethylcellulose, alkali metal salts of polyacrylicacids, polyacrylamides, polyvinyl alcohol, ethylene maleic anhydridecopolymers, polyvinyl ethers, hydroxypropyl cellulose, polyvinylmorpholinone, polymers and copolymers of vinyl sulfonic acid,polyacrylates, polyacrylamides, polyvinyl pyridine or the like. Othersuitable polymers can include hydrolyzed acrylonitrile grafted starch,acrylic acid grafted starch, and isobutylene maleic anhydridecopolymers, and mixtures thereof.

The hydrogel polymers are desirably sufficiently cross-linked to renderthe materials substantially water-insoluble. Cross-linking may, forexample, be by irradiation or by covalent, ionic, van der Waals orhydrogen bonding. Suitable materials are available from variouscommercial vendors, such as Dow Chemical Company, Hoechst-CelaneseCorporation, Stockhausen, Inc., and Allied-Colloid. Typically, thehigh-absorbency material is capable of absorbing at least about 15 timesits weight in water, and desirably is capable of absorbing more thanabout 25 times its weight in water.

The high-absorbency material can be distributed or otherwiseincorporated into the absorbent pad 58 employing various techniques. Forexample, the high-absorbency material can be substantially uniformlydistributed among the fibers comprising the absorbent pad 58. Thematerials can also be non-uniformly distributed within the absorbent pad58 fibers to form a generally continuous gradient with either anincreasing or decreasing concentration of high-absorbency material, asdetermined by observing the concentration moving inward from the backingmember 22. Alternatively, the high-absorbency material can comprise adiscrete layer separate from the fibrous material of the absorbent pad58, or can comprise a discrete layer integral with the absorbent pad 58.

The absorbent pad 58 may also include a wrap layer 80 to help maintainthe integrity of the fibrous core. (See FIG. 3a.) This wrap layer 80 maycomprise a cellulosic tissue or spunbond, meltblown or bonded-carded webmaterial composed of synthetic polymer filaments, such as polypropylene,polyethylene, polyesters or the like or natural polymer filaments suchas rayon or cotton.

The absorbent pad 58 should have an aqueous liquid capacity great enoughto absorb discharges from about 10 grams to about 1000 grams. Theabsorbent pad 58 should preferably have a capacity (described below) anda thickness preferably less than about 25 mm, thus providing a non-bulkyand flexible fit. The capacity of the absorbent pad 58 should have atotal capacity of about 200 grams to about 1300 grams. Preferably, theabsorbent pad 58 should have a total capacity of at least about 300grams to about 1200 grams. More preferably, the total capacity of theabsorbent pad 58 should be from about 400 grams to about 800 grams.

The total capacity of the absorbent pad 58 is determined using theabsorbent pad 58 of the absorbent garment 20, the body-side liner 40,the backing member 22, and the outer member 38. The saturated retentioncapacity is a measure of the total absorbent capacity of an breathableabsorbent garment 20, in this case an undergarment. The saturatedretention capacity is determined as follows. The breathable absorbentgarment 20 to be tested, having a moisture content of less than about 7weight percent, is then weighed and submerged in an excess quantity ofthe room temperature (about 230° C.) saline solution described below.The material is allowed to remain submerged for 20 minutes. After 20minutes the breathable absorbent garment 20 is removed from the salinesolution and placed on a Teflon™ coated fiberglass screen having 0.25inch openings (commercially available from Taconic Plastics Inc.,Petersburg, N.Y.) which, in turn, is placed on a vacuum box and coveredwith a flexible rubber dam material. A vacuum of 3.5 kilopascals (0.5pounds per square inch) is drawn in the vacuum box for a period of 5minutes. The breathable absorbent garment 20 is weighed. The amount ofaqueous liquid retained by the material being tested is determined bysubtracting the dry weight of the breathable absorbent garment 20 fromthe wet weight of the breathable absorbent garment 20 (after applicationof the vacuum) and is reported as the saturated retention capacity ingrams of aqueous liquid retained.

The saline solution is an aqueous solution of about 0.9 percent sodiumchloride by weight. A suitable product is S/P™ Certified Blood Salinecommercially available from Baxter Diagnostics in McGaw Park, Ill.

The absorbent pad 58 can be made from a blend of fibers comprising about15 to about 30 weight percent polypropylene fibers and about 85 to about60 weight percent wood pulp fluff fibers and having a basis weight of 80to about 250 gsm. The absorbent pad 58 may be formed on a tissue or aspunbonded carrier sheet, or may be formed without a carrier sheet. Itis contemplated that the absorbent pad 58 can also be made from a blendof fibers comprising between about 10 weight percent and about 90 weightpercent polypropylene or polyethlene fibers and between about 90 weightpercent and about 10 weight percent wood pulp fluff fibers. Theabsorbent pad 58 could also be made from 100 weight percent wood pulpfluff fiber. The basis weight can range between about 80 gsm and about1000 gsm. The absorbent pad 58 can also be a batt of meltblown fiberssuch as polypropylene, polyethylene, polyester and the like, and mayalso be a bonded carded web of synthetic or natural fibers, a compositeof meltblown fibers of polypropylene, polyethylene, and polyester mixedwith a cellulosic material, or any other suitable absorbent material.

The absorbent pad 58 provides the feature of being able to transportaqueous liquid in what can be characterized as in an x- and y directionand in a z-direction. The transport of aqueous liquid in the z directionis movement of a wicking nature where the aqueous liquid moves away fromthe body of the wearer. The transport of aqueous liquid in thex-direction and y-direction is movement and/or wicking of aqueous liquidalong the length and width of the absorbent layer. As can beappreciated, the movement of aqueous liquid both away from the wearerand along the length and width of the absorbent layer results in anincrease in the utilization of the area of the absorbent layer since theaqueous liquid moves towards the distal ends of the absorbent layer, andthe result is an improvement of the absorption characteristics of theabsorbent layer.

As illustrated in FIGS. 2 and 4b, the absorbent pad 58 has a width thatis measured between the side edges 62 and 64 thereof. The absorbent pad58 has a length that is measured between the front end and the back endedges 66 and 68 thereof. The width and length of the absorbent pad 58are each less than the corresponding width and length of the container74 comprised of the backing member 22 and the aqueous liquid perviousbody-side liner 40. The width of container 74 is measured between theside edges 26 and 28 thereof, and the length of the container 74 ismeasured between the front and back edges 30 and 32.

The width of the crotch region 35 between the leg elastics 96 and 108should be wide enough to accommodate the absorbent pad 58 between theside edges 26 and 28 of the absorbent garment 20 without having theabsorbent pad 58 obstruct the leg elastics 96 and 108. This allows theleg elastics 96 and 108 to contract and draw up the sides of the crotchregion 35 creating a bucket with walls of the body-side liner 40 andbacking member 22 to keep bodily exudates from leaking out of theabsorbent garment 20 and to accommodate more sizes of individuals.

The width of the crotch region 35 should not be so wide as to seem bulkyor uncomfortable, but a suitable width is at least about 2.5 inches (64mm) between the leg elastics 96 and 108. The width is advantageouslyranges from about 2.5 inches (64 mm) to about 14.0 inches (356 mm).Typically the width of the crotch region 35 between the leg elastics 96and 108 ranges from about 3.5 inches (89 mm) to about 8 inches (203 mm).

The crotch region 35 is at least about 0.25 inch (6 mm) wider than thewidth of the absorbent pad 58. The crotch region 35 is from about 0.25inch (6 mm) to about 4 inches (102 mm) wider than the absorbent pad 58.Typically the crotch region 35 is from about 0.5 inch (13 mm) to about 3inches (76 mm) wider than the absorbent pad 58 and more typically fromabout 0.5 inch (13 mm) to about 2 inches (51 mm) wider. Preferably, eachof the leg elastics 96 and 108 are from about 0.2 inch (5 mm) to about0.8 inch (20 mm) wide. More preferably, the width of each leg elastics96 and 108 is from about 0.2 inch (5 mm) to about 0.4 (10 mm). Theoverall width of the crotch region 35 includes the width between the legelastics 96 and 108, the width of the leg elastics 96 and 108 and thematerial (at least including the outer member 38, the backing member 22,and the body-side liner 40) between the leg elastics 96 and 108 and theside edges 26 and 28 of the breathable absorbent garment 20.

Preferably, the material (at least including the outer member 38, thebacking member 22, and the body-side liner 40) on the longitudinal edgesoutside the leg elastics 96 and 108 is less than about 0.5 inch (13 mm).More preferably, the material is less than about 0.125 inch (3 mm).

The overall length of the absorbent pad 58 should be adequate to helpprevent aqueous liquid strike through when sleeping or sitting. Thisoverall length is at least about 12 inches (305 mm) thus extendingbeyond the crotch region 35 along the longitudinal centerline A—A of thebreathable absorbent garment 20. Alternatively, the length should be inthe range of about 12 inches (305 mm)to about 30 inches (762 mm), moretypically ranging from about 15 inches (381 mm) to about 23 inches (584mm). A common range is from about 15 inches (381 mm) to about 21 inches(533 mm) in length, more typically ranging from about 17 inches (432 cm)to about 20 inches (508 mm).

The width of the absorbent pad 58 extending beyond the crotch region 35should be at least as wide as the width of the crotch region 35. Thewidth of the absorbent pad 58 could be narrowed beyond the crotch region35 but may compromise the leakage containment. In some cases, the widthof the absorbent pad 58 is widened beyond the crotch region 35. Thewidth of the absorbent pad 58 extending beyond the crotch region 35 isfrom about 2.5 inches (64 mm) to about 12 inches (305 mm), alternativelyfrom about 4.0 inches (102 mm) to about 10 inches (254 mm). A commonrange is from about 7 inches (178 mm) to about 9 inches (229 mm).

The present invention contemplates various shapes of the absorbent pad58. One preferred composite has a non-rectangular shape such as anhourglass or I-beamed shaped absorbent pad 58 which provide extensivecoverage in the seat of the finished breathable absorbent garment 20.Another preferred absorbent pad 58 embodiment is rectangular in shapewith rounded ends. The essentially rectangular-shaped absorbent pad 58(i.e. an hourglass shape) is more preferred since it can be squared offat the ends to provide a smoother appearance in the back of thebreathable absorbent garment 20 while providing a more comfortablebody-contouring fit.

More specifically, the width of the absorbent pad 58 is between about 40percent and about 90 percent of the width of the container 74 comprisedof the impervious backing member 22 and pervious body-side liner 40. Thelength of the absorbent pad 58 is between about 30 percent and 100percent of the length of the container 74 comprised of the imperviousbacking member 22 and the pervious body-side liner 40. More typically,the length of the absorbent pad 58 is between about 40 percent and about90 percent of the length of the container 74, most typically betweenabout 50 percent and 70 percent of the length of the container 74.

In the specific embodiment, the absorbent pad 58 has a length equal toabout 19 inches (48.3 cm), and a width equal to about 4.5 inches (11.4cm). The width of the absorbent pad can vary, but is typically betweenabout 2.5 inches (6.4 cm) and about 5 inches (12.7 cm) narrower than thewidth of the impervious backing member 22.

The absorbent pad 58 is typically positioned so as to be symmetricalabout the central longitudinal axis A—A of the breathable absorbentgarment 20. It need not be symmetrical about the central transverse axisB—B of the breathable absorbent garment 20. In other words, the sideedges 62 and 64 of the absorbent pad 58 are equi-distant from side edges48 and 50 of the aqueous liquid pervious body-side liner 40,respectively. The front end and back end edges 66 and 68 respectively ofthe absorbent pad 58 are not necessarily equi-distant from the front andback edges 44 and 46 of the aqueous liquid pervious body-side liner 40,respectively. The absorbent pad 58 is disposed in the front waist region37 and the crotch region 35. The leg elastics 96 and 108 effectivelyseal between the body of the wearer and the breathable absorbent garment20 so as to provide good containment properties in the crotch region 35.

The leg elastic 96 has a front edge 98, a back edge 100, an exteriorside edge 102, and an interior side edge 104. The leg elastic 96 isaffixed adjacent the front edge 48 of the aqueous liquid perviousbody-side liner 40 so as to be spaced inwardly therefrom. The legelastic 96 is positioned so that the front edge 98 and the back edge 100are equi-distant from their respective front and back edges 44 and 46 ofthe aqueous liquid pervious body-side liner 40. However, the leg elastic96 can be positioned other than in an equi-distant arrangement relativeto their front and back edges 98 and 100 and the front and back edges 44and 46 of the aqueous liquid pervious body-side liner 40.

The second leg elastic 108 has a front edge 110, a back edge 112, aninterior side edge 114, and an exterior side edge 116. The leg elastic108 is affixed to the aqueous liquid pervious body-side liner 40 so asto be adjacent to the side edge 50 thereof, and is spaced inwardly ofthe side edge 50. The leg elastic 108 is positioned so that its frontedge 110 and back edge 112 are spaced equi-distant from their respectivefront and back edges 44 and 46 of the aqueous liquid pervious body-sideliner 40. The leg elastic 108 can also be positioned other than in anequidistant arrangement.

While the leg elastics 96, and 108 can be designed to closely follow theedge of the absorbent pad 58 outside of the crotch region 35, moving theleg elastics 96 and 108 away from the absorbent pad 58, the absorbentpad 58 interfers less with the function of the leg elastics 96 and 108,providing better gasketing around the legs of the wearer. In addition,as absorbent pad 58 swells as it absorbs bodily discharges, the legelastics 96 and 108 so positioned are better able to remain in contactwith and conformed to the wearer's body. Such a placement of the legelastics 96 and 108 is especially beneficial in garment 20 having legcutouts, as fit protection, and comfort of the garment 20 are improved.

In a preferred embodiment, leg elastics 96 and 108, are attached to thebreathable absorbent garment 20 sandwiched between the backing member 22and the body-side liner 40, in generally a stretched state by meansknown in the art, including ultrasonic bonding, heat/pressure bonding oradhesively bonding. Materials suitable for the elastics include a widevariety including but not limited to elastic strands, yarn rubber, flatrubber, elastic tape, film-type rubber, polyurethane and elastomeric,tape-like elastomeric or foam polyurethane or formed elastic ornon-elastic scrim. Suitable material is sold under the name LYCRA® XA bythe DuPont Company located in Wilmington, Del. Each elastic may beunitary, multi-part or composite in construction before integrating intothe breathable absorbent garment 20.

In an alternative embodiment, leg elastics 96 and 108, are attached tothe breathable absorbent garment 20 sandwiched between the outer member38 and the backing member 22 in generally a stretched state by meansknown in the art, such as ultrasonic bonding, heat/pressure bonding oradhesively bonding.

The leg elastics 96 and 108 are from about 0.0625 inch (1.6 mm) to about1 inch (25 mm) wide, more typically from about 0.25 inch (6 mm) to about1 inch (25 mm), and most typically from about 0.25 inch (6 mm) to about0.75 inch (18 mm) such as 0.5 inch (13 mm). The leg elastic 96 and 108is applied under an elongation of from about 100% to about 350%, moretypically under an elongation of from about 150% to about 300%, and mosttypically under an elongation of from about 225% to about 275%.

The leg elastics 96 and 108 may comprise threads, strands, ribbons,bands, film, elastic nonwovens, or composite. The threads, strands,ribbons, or bands may be multiple and may be applied as a composite. Thenumber of pieces of elastic material comprising the leg elastic 96 and108 ranges from about 1 to about 6, more typically from about 2 to about5, and most typically from about 3 to about 4. Preferably, when the legelastics 96 and 108 are threads, 1 to 6 threads are used as the legelastics 96 and 108, and the threads are spaced from about 0.0625 inch(1.6 mm) to about 0.5 inches (13 mm), more preferably from about 0.0625inch (1.6 mm) to about 0.25 inch (6 mm), and most preferably about 0.083inch (2 mm) apart.

The threads may be made of any suitable elastomeric material. Onesuitable material is spandex such as LYCRA® threads available fromDuPont located in Wilmington, Del. Suitable leg elastics 96 and 108include threads having a decitex (g/10000m) of from about 470 to about1200, more typically from about 620 to about 1000, and most typicallyfrom about 740 to about 940 for leg elastics 96 and 108 comprising fromabout 3 to about 6 threads. Adhesive 118, typically applied in ameltblown or swirl pattern using currently known technology, is used tobond the leg elastics 96 and 108 to the outer member 38, the body-sideliner 40, or the backing member 22. Preferably the adhesive 118 isapplied only to the leg elastics 96 and 108. A suitable adhesiveincludes, for example, Findley H2096 hot melt adhesive which isavailable from Ato Findley Adhesives located in Milwaukee, Wis.

In one embodiment, to provide a snug fit around the legs of the wearerand to draw up the sides of the crotch region 35 to form a cradlestructure around the absorbent pad 58, the leg elastics 96 and 108 areapplied to the backing member 22 or the body-side liner 40 under anelongation of about 200% to about 250%. The leg elastics 96 and 108 aresandwiched between the backing member 22 and the body-side liner 40under an elongation more preferably of about 200%.

In another embodiment providing a snug fit around the legs of the wearerand drawing the sides of the crotch region 35 up to form a cradlestructure around the absorbent pad 58, the leg elastics 96 and 108 areapplied to the outer member 38 or the backing member 22 under anelongation of about 200% to about 250%. The leg elastics 96 and 108 aresandwiched between the outer member 38 and the backing member 22, underan elongation more preferably of about 200%.

In the specific embodiment, the leg elastics 96 and 108 are made ofurethane. However, it is contemplated that the leg elastics 96 and 108can be made of natural rubber or other synthetic elastic material.

When stretched for adherence to the garment, the leg elastics 96 and 108each have a length of about 14 inches (35.6 cm) and a width of about0.42 inches (1.06 cm). When the leg elastics relax, they each are of alength equal to about 16.5 cm and a width of about 1.27 cm.

A pair of slits 120 and 122, such as button holes, are contained in thecontainer 74 comprised of the aqueous liquid pervious body-side liner 40and the aqueous liquid impervious backing member 22 adjacent the frontedge 30 of the breathable absorbent garment 20. Another pair of slits124 and 126, such as button holes, are contained in the container 74comprised of the aqueous liquid pervious body-side liner 40 and aqueousliquid impervious backing member 22 adjacent the back edge 32 of thebreathable absorbent garment 20. A strap 130, having retainers 132 and134, such as buttons, each at opposite ends, extends between the slits120 and 124. Another strap 136, having retainers 138 and 140, such asbuttons, each at opposite ends, extends between the slits 122 and 126.This support system is described in the U.S. Pat. No. 4,315,508 issuedFeb. 16, 1982, to Bolick, which is incorporated herein by reference.

Still, other means for securing the garment around the individualincludes mechanical type fasteners. These include snaps, buckles,clasps, hooks and loops, end extensions, tabs, adhesive tapes, and thelike which are designed or adapted to interlock or engage some type of acomplimentary device or the outer cover of the garment. In addition,elasticized fasteners are also used in assuring better fit of suchgarments. Other absorbent garments 20 may include fully encircling orpre-fastened waist bands.

A breathable microporous film can be treated, in accord with the presentinvention, to create a breathable film backing member 22 having regionsof varied breathability. In reference to FIG. 5, microporous film 212 isunwound from supply roll 214 and fed into nip 216 created by first andsecond nip rolls 218 and 220. The first nip roll 218 can have apatterned surface such as raised surface 222 whereby the film enteringnip 216 adjacent raised surface 222 experiences compacting pressure. Thesecond nip roll 220 can be a smooth or unpatterned roll. The microporousfilm 212 is desirably heated and can be heated prior to entering nip 216or upon entering the roller assembly. Desirably the film is heated byusing one or more heated rolls. The pressure and heat applied to themicroporous film 212 reduces the size and/or number of pores within themicroporous film thereby reducing the breathability of the film in thoseselected areas. Thus, a breathable microporous film can be made havingregions of controlled breathability. Still in reference to FIG. 5, amicroporous film is created having first breathable regions 224 andsecond regions 226 having a breathability or WVTR lower than that of thefirst breathable regions 224. The treated film can then be wound on awinder roll 228 or further processed and/or converted as desired.

Suitable microporous films for practicing the present invention includebreathable microporous films having a WVTR of at least 500 g/m²/24hours, and more desirably having a WVTR in excess of 1500 g/m²/24 hours,2500 g/m²/24 hours or 3500 g/m²/24 hours. Desirably, the breathablemicroporous film substrate has a WVTR between about 2000 g/m²/24 hoursand about 7000 g/m²/24 hours. Thin breathable microporous film can beformed by any one of various methods known in the art. Examples ofmicroporous films suitable for use with the present invention include,but are not limited to, those described in the following references U.S.Pat. No. 5,800,758 issued Sep. 1, 1998 to Topolkaraev et al.; U.S. Pat.No. 4,777,073 issued Oct. 11, 1988, to Sheth; and, U.S. Pat. No.4,867,881 issued Sep. 19, 1989, to Kinzer; the entire contents of theaforesaid references are incorporated herein by reference.

Additional examples of microporous films suitable for use with thepresent invention include, but are not limited to, those described inthe following references: U.S. Pat. No. 4,613,544 issued Sep.23, 1986,to Burleigh; U.S. Pat. No. 4,833,026 issued May 23, 1989,to Kausch; U.S.Pat. No.4,863,788issued Sep.5, 1989,to Bellairs et al.; U.S. Pat. No.4,878,974 issued Nov. 7, 1989, to Kagawa; U.S. Pat. No. 4,620,956 issuedNov.4, 1986, to Hamer; U.S. Pat. No. 4,620,955 issued Nov.4, 1986, toKono et al.; and, U.S. Pat. No. 5,352,513 issued Oct.4, 1994, toMrozinski et al.; the entire contents of the aforesaid references areincorporated herein by reference.

A preferred breathable microporous film can comprise a stretched-filledfilm which includes a thermoplastic polymer and filler. These (andother) components can be mixed together, heated and then extruded into amonolayer or multilayer film. The filled film may be made by any one ofa variety of film forming processes known in the art such as, forexample, by using either cast or blown film equipment. The thermoplasticpolymer and filler can be stretched in at least one direction, therebyreducing the film gauge or thickness and creating a network ofmicropores throughout the film of a size and frequency to achieve thedesired level of breathability. Such films, prior to stretching,desirably have a basis weight of less than about 100 g/m² and even moredesirably less than about 60 g/m². Upon stretching the multilayer filmdesirably has a basis weight of less than about 60 g/m² and even moredesirably between about 15 and 35 g/m². Suitable films can also includemultilayer films having at least one microporous layer such as, forexample, those described in the references cited above.

The microporous films can comprise known film forming polymers whichare, by mechanical and/or thermal treatment, permanently deformable.Mechanically deformable polymer films are believed to be suitable foruse with the present invention (e.g. soft rubbers). Desirably themicroporous film is made from a thermoplastic polymer. Preferredthermoplastic polymers used in the microporous films of the presentinvention include, but are not limited to, polyolefins includinghomopolymers, copolymers, terpolymers and blends thereof. Additionalfilm forming polymers suitable for use with the present invention, aloneor in combination with other polymers, include ethylene vinyl acetate,ethylene ethyl acrylate, ethylene acrylic acid, ethylene methylacrylate, ethylene normal butyl acrylate, polyester, polyethyleneterephthalate, polyamides (e.g. nylon), ethylene vinyl alcohol,polystyrene, polyurethane, polybutylene, and polybutylene-terephthalate.However, polyolefin polymers are preferred such as, for example,polymers of ethylene and propylene as well as copolymers, terpolymersand blends thereof; examples include, but are not limited to, linear lowdensity polyethylene (LLDPE) and ethylene-propylenecopolymer blends. Themicroporous films can comprise elastic or inelastic polymers. However,with elastic microporous films sufficient energy, e.g. heat and/orpressure, should be imparted to “set” the treated region of the film.

Once the breathable microporous film has been formed, that is the finepore network has been created across the film, the microporous film canbe treated to impart zoned or controlled regional breathability to thefilm. The microporous film can be made in-line or made previously andunwound from a supply roll. Selected regions of the microporous film aretreated with sufficient energy (e.g. pressure and/or heat) to reduce thenumber and/or size of pores therein and thereby reduce and/orsubstantially eliminate the breathability previously imparted to thefilm in that region. For example, the microporous film can be passedthrough a pair of patterned nip rollers which apply a pre-determinedamount of pressure to reduce the pore structure to a desired degree. Thedegree of pressure applied by the nip rolls will vary with respect tothe type of polymer comprising the microporous film, the thickness ofthe microporous film, the temperature of the film and the level ofbreathability desired in the zone treated regions.

Desirably one of the nip rolls is patterned so as to have a raisedsurface. The rollers can have varied patterns to create the zonedbreathability in the film as desired. However, small discrete raisedprojections on the nip roll can create a film with degraded barrierproperties and/or strength. Thus, the raised surface of the roller(s) issuch that the corresponding treated regions of the film extend at least3 cm in the CD and MD and more desirably at least 5 cm×5 cm in the CDand MD. Further, the raised surface or can extend at least 10 cm ineither the CD or MD direction. In a further aspect of the invention, thetreated regions desirably comprise from about 5% to about 90% of thearea of the film. In a preferred embodiment of the present invention thetreated regions comprise a contiguous area comprising from about 5% toabout 75% of the area of the overall film and more desirably comprisefrom about 15% to about 60% of the area of the film. In a furtherembodiment, the regions can comprises a plurality of regions ofintermediate and low breathability. The regions of low and intermediatebreathability desirably form a single contiguous area and which can, inone aspect, be disposed about the central portion of the film. However,the treated regions can comprise several non-contiguous regions.

In one embodiment of the present invention, the patterned nip roll canhave a raised surface which is continuous. As an example, raised surface222 can extend around the circumference of a roll such as first nip roll218 shown in FIGS. 5 and 7. First nip roll 218 having raised surface 222is shown in FIG. 7 with an enlarged view of the raised surface edge.Raised surface 222 can have a squared off edge although it isadvantageous to employ a rounded or tapered edge along the raisedsurface of the nip roll. Each of the nip rolls desirably have a hardsurface, such as steel rolls, although other materials are believedsuitable with the present invention. As an example, it is believed arubber coated roll may be advantageous when used in connection with apatterned steel roll. In a further aspect, the patterned roll can haveshims along the edge of the patterned roll at the same height of theraised surface to stabilize the rolls and/or improve processing of thefilm. Desirably the film is of a size and also fed into the nip suchthat it does not pass under the shims.

The location of the raised surface(s) can be placed upon the patternednip roll to treat the microporous film in the desired locations. Forexample, a patterned roll having a continuous raised surface about thecenter of the roll can be used to create a zoned breathabilitymicroporous film, such as shown in reference to FIG. 5, having highlybreathable regions 224 adjacent the opposed edges of the film andcentral region 226 of reduced breathability therebetween. The reducedbreathability region 226 can extend continuously in the machinedirection of the microporous film. In a further aspect of the invention,when using a continuous raised surface that extends around the entirecircumference of a given length of the roll, the nip pressure can bevaried in order to further modify the breathability of the correspondingregion of the film. For example, the hydraulic pressure on the rollerscould be oscillated in order to achieve varied levels of breathabilityextending in the machine direction.

In a further aspect of the invention, the raised surface or surfaces canbe shaped to create correspondingly shaped regional breathability to themicroporous film. In reference to FIG. 8, patterned roll 219 can haveraised surface 223 and lower surface 225. Microporous film 212 is fedthrough nip 221 created by rolls 219 and 220 thereby creating a filmhaving first region 229 and second region 227A wherein first region 229has a higher WVTR than second region 227A. Further, it is believed thatcontinuous region 227 itself will have varied levels of breathability.Narrow sections, second region 227A, will have a lower WVTR than widesections, third region 227B. It is believed that the pounds per linearinch (typically referred to as pressure/unit area) experienced bymicroporous film 212 will be greater in the narrower sections therebyeffecting a greater decrease in film breathability in those areas.

In a further aspect, the raised surface can be discontinuous in thesense that the raised surface extends around only a portion of the rollscircumference. In reference to FIG. 9, patterned roll 230 has raisedsurface 232 and lower surface 234 wherein raised surface 232 extendsaround less than the entire periphery of roll 230. Treatment of amicroporous film with such a roll will create first region 236 andsecond region 238 whereby first region 236 has greater breathabilitythan second region 238. Further, second region 238 will be separated byportions of first region 236 in the machine direction.

As a further example, a patterned roll can have multiple stepped raisedsurfaces to create a breathability gradient across the CD of the film.In reference to FIGS. 10 and 11, patterned roll 240 has first surface242, a second surface 244 and a third surface 246 wherein second surface244 and third surface 246 are raised surfaces relative to first surface242. Further, third surface 246 can be disposed between first and secondsurfaces 242 and 244 having an in intermediate height relative to theadjacent surfaces. The resulting zoned breathable film 248 film willhave first region 250 of high breathability, second region 252 of lowbreathability and third region 254 of intermediate breathability. In afurther aspect of the invention and in reference to FIG. 12, patternedroll 260 can utilize a crowned or rounded roll, having raised surfaces262 while having a more regular surface. A film treated in accord withsuch a patterned roller will have regions of varied breathability with abreathability gradient across the CD of the film as opposed tosubstantially distinct regions of breathability.

In regard to the height of the raised surfaces of the roll(s), thisheight will vary with respect to the thickness of the untreatedmicroporous film, the level of breathability desired and the hardness ofthe nip rolls. Desirably the raised surface of the nip has a height ofat least 10 microns and more desirably has a height of between abouthalf the thickness of the untreated film and about 1 mm.

In addition to pressure, additional energy such as thermal energy can beapplied to the film. The particular combination of pressure and heatapplied to the film will vary with regard the particular polymers andfillers involved and the desired characteristics of the treated films.Generally speaking, at equivalent pressures, films heated to highertemperatures experience a greater decrease in WVTR and/or thickness.Further, it has been found that CD strength is improved by heating thefilm to a higher degree. Desirably sufficient thermal energy is appliedto heat the film to about the polymer softening point and is furtherdesirable that the film not be heated to or above its melting point.However, although use of relatively higher film temperatures arebelieved suitable for use with the present invention, it is believedthat at such temperatures it will be difficult to achieve a controlledlevel of film breathability. The general relationship between nippressure, film temperature and impact on film WVTR for thermoplasticpolymers is further exemplified in the actual examples set forth below.

The zoned treatment of the microporous film acts to reduce the numberand/or size of the pores in the treated regions thereby reducing theWVTR or breathability in those same regions. In reference to FIG. 5 and6, the zone treated microporous film can have a first substantiallyuncompressed region 224 which has a higher level of breathability thanthe second compressed region 226 of the film. The compressed or secondregion 226 will substantially correspond to those areas of the film towhich heat and/or pressure is applied via the raised regions 222 of thepatterned nip roll 218. In addition, the treated regions will, despitehaving a lower WVTR, typically have a thickness which is thinner thanthe substantially uncompressed regions. Although the relative thicknesswill vary, the compressed regions typically have a thickness which isless than about 95% of the thickness of the untreated region and inother embodiments can be less than about 90% or even less than about 80%of the thickness of the untreated regions. In this regard it is believedthat decrease in film thickness provides a corresponding decrease inWVTR. Further, as a result of the treatment, some retraction may occurchanging the film basis weight. FIGS. 13 and 14, respectively, arephotomicrographs of a cross-section of a substantially uncompressedregion of filled microporous film and a compressed region of the samefilm. In addition, with stretched-filled microporous films of about 35g/m² or less, upon application of sufficient heat and pressure, thecompressed regions can become translucent and/or exhibit decreasedopacity relative to the substantially uncompressed regions.

In another embodiment of the present invention, a breathable microporousfilm 412 can be treated, in accord with the present invention, to createa breathable film backing member 22 having regions of variedbreathability using adhesives or other coating materials. In referenceto FIG. 15a and 15 b, microporous film 412 is unwound from supply roll414. A meltblown adhesive applicator 416, including but not limited to aNordson Control Coat CC-200 available from the Nordson Corporation atNorcross, Ga., applies an adhesive layer 418 to the body-side surface420 of the microporous film 412. The adhesive layer 418 is applied in anopen pattern and as such, has minimal effect on the breathability of themicroporous film 412. A second adhesive applicator 422, including butnot limited to a Nordson EP45 contact type coating head available fromthe Nordson Corporation at Norcross, Ga., is pulsed to apply an adhesivecoat layer 424 on to areas where less breathability is desired. Theamount of adhesive applied in the adhesive coat layer 424 depends on thedesired reduction in breathability. The adhesive coat layer 424 appliedto the microporous film 412 reduces the size or number of pores withinmicroporous film 412 at least partially covers or fills the pores,thereby reducing the breathability of the film in these selected areas.Thus, a breathable microporous film 412 can be made having regions ofcontrolled breathability. As shown in FIG. 16a and 16 b, a microporousfilm 412 is created having a first breathable regions 426 and secondregions 428 having a breathability or WVTR lower than that of the firstregions 426. The treated film 412 can then be wound on a winder roll 430or further processed or converted as desired.

The term “adhesive” or “adhesives” as used herein includes, but is notlimited to, any material which will adhere to the microporous film whenapplied by some coating apparatus, thereby reducing the WVTR of themicroporous film where the adhesive has been applied.

The adhesive layer 418 can be applied over the entire body-side surface420 of the microporous film 412 or the adhesive layer 418 can be appliedin the areas only where the adhesive coat layer 424 will not be applied.The adhesive layer 418 is typically a construction adhesive, theadhesive used to attach the various components of product into which themicroporous film 412 is incorporated. The adhesive layer 418 preferablyis from about 1 gsm to about 7 gsm, more preferably from about 2 gsm toabout 5 gsm, and most preferably 3.2 gsm. An example of a constructionadhesive is 34-5610 from the National Starch and Chemical Company inBridgewater, N.J.

In another embodiment of the present invention, a breathable microporousfilm 412 can be treated, in accord with the present invention, to createa breathable film backing member 22 having regions of variedbreathability using adhesives. In reference to FIG. 15a, microporousfilm 412 is unwound from supply roll 414. An adhesive applicator 422,including but not limited to a Nordson EP45 contact type coating headavailable from the Nordson Corporation at Norcross, Ga., is pulsed toapply an adhesive coat layer 424 on to areas where less breathability isdesired. The amount of adhesive applied in the adhesive coat layer 424,as well as the type of adhesive and the type of adhesive application,determines the desired reduction in breathability. The adhesive coatlayer 424 applied to the microporous film 412 at least partially coversor fills the pores within the microporous film 412, thereby reducing thesize or number of pores within microporous film 412 thereby reducing thebreathability of the film in these selected areas. Thus, a breathablemicroporous 412 can be made having regions of controlled breathability.As shown in FIG. 16a and 16 b, a microporous film 412 is created havinga first breathable regions 426 and second regions 428 having abreathability or WVTR lower than that of the first regions 426. Thetreated film 412 can then be wound on a winder roll 430 or furtherprocessed or converted as desired.

While it may be typical to apply the adhesive coat layer 424 to thebody-side surface 420 of the microporous film 412, the adhesive coatlayer 424 may be applied to the garment-side surface 421 of themicroporous film 412.

In certain circumstances, it may be beneficial to leave the portions ofthe backing member 22 free of the adhesive coat layer 424 where the legelastics 96 and 108 are positioned as the adhesive coat layer 424 mayinterfere with the application of the leg elastics 96 and 108 during theconstruction of the breathable absorbent garment 20.

Suitable microporous films for practicing this embodiment of the presentinvention include breathable microporous films having a WVTR of at least500 g /m²/24 hours, and more desirably having a WVTR in excess of 1500g/m²/24 hours, 2500 g/m²/24 hours or 3500 g/m²/24 hours. Desirably, thebreathable microporous film substrate has a WVTR between about 2000g/m²/24 hours and about 7000 g/m²/24 hours. Thin breathable microporousfilm can be formed by any one of various methods known in the art.Examples of microporous films suitable for use with the presentinvention include, but are not limited to, those described in thefollowing references: U.S. Pat. No. 5,800,758 issued Sep. 1, 1998 toTopolkaraev et al.; U.S. Pat. No.4,777,073 issued Oct.11, 1988, toSheth; and, U.S. Pat. No. 4,867,881 issued Sep. 19, 1989, to Kinzer; theentire contents of the aforesaid references are incorporated herein byreference.

Additional examples of microporous films suitable for use with thepresent invention include, but are not limited to, those described inthe following references: U.S. Pat. No. 4,613,544 issued Sep. 23, 1986,to Burleigh; U.S. Pat. No. 4,833,026 issued May 23, 1989, to Kausch;U.S. Pat. No. 4,863,788 issued Sep. 5, 1989, to Bellairs et al.; U.S.Pat. No. 4,878,974 issued Nov. 7, 1989, to Kagawa; U.S. Pat. No.4,620,956 issued Nov.4, 1986, to Hamer; U.S. Pat. No. 4,620,955 issuedNov.4, 1986, to Kono et al.; and, U.S. Pat. No. 5,352,513 issued Oct.4,1994, to Mrozinski et al.; the entire contents of the aforesaidreferences are incorporated herein by reference.

A preferred breathable microporous film can comprise a stretched-filledfilm which includes a thermoplastic polymer and filler. These (andother) components can be mixed together, heated and then extruded into amonolayer or multilayer film. The filled film may be made by any one ofa variety of film forming processes known in the art such as, forexample, by using either cast or blown film equipment. The thermoplasticpolymer and filler can be stretched in at least one direction, therebyreducing the film gauge or thickness and creating a network ofmicropores throughout the film of a size and frequency to achieve thedesired level of breathability. Such films, prior to stretching,desirably have a basis weight of less than about 100 g/m² and even moredesirably less than about 60 g/m². Upon stretching the multilayer filmdesirably has a basis weight of less than about 60 g/m² and even moredesirably between about 15 and 35 g/m². Suitable films can also includemultilayer films having at least one microporous layer such as, forexample, those described in the references cited above.

The microporous films can comprise known film forming polymers whichare, by mechanical and/or thermal treatment, permanently deformable.Mechanically deformable polymer films are believed to be suitable foruse with the present invention (e.g. soft rubbers). Desirably themicroporous film is made from a thermoplastic polymer. Preferredthermoplastic polymers used in the microporous films of the presentinvention include, but are not limited to, polyolefins includinghomopolymers, copolymers, terpolymers and blends thereof. Additionalfilm forming polymers suitable for use with the present invention, aloneor in combination with other polymers, include ethylene vinyl acetate,ethylene ethyl acrylate, ethylene acrylic acid, ethylene methylacrylate, ethylene normal butyl acrylate, polyester, polyethyleneterephthalate, polyamides (e.g. nylon), ethylene vinyl alcohol,polystyrene, polyurethane, polybutylene, and polybutylene terephthalate.However, polyolefin polymers are preferred such as, for example,polymers of ethylene and propylene as well as copolymers, terpolymersand blends thereof; examples include, but are not limited to, linear lowdensity polyethylene (LLDPE) and ethylene-propylene copolymer blends.The microporous films can comprise elastic or inelastic polymers.However, with elastic microporous films sufficient energy, e.g. heatand/or pressure, should be imparted to “set” the treated region of thefilm.

Once the breathable microporous film 412 has been formed, that is thefine pore network has been created across the film, the microporous film412 can be treated to impart zoned or controlled regional breathabilityto the film. The microporous film 412 can be made in-line or madepreviously and unwound from a supply roll. Selected regions of themicroporous film are treated with sufficient adhesive to at leastpartially cover or fill the pores of the film, thereby reducing thenumber and/or size of pores therein and thereby reduce and/orsubstantially eliminate the breathability previously imparted to thefilm in the treated region. The breathability is directly dependent uponthe thickness (the amount of adhesive or the percentage of coverage),the type of adhesive used, and the type of adhesive application used inapplying the adhesive coat layer 424 to the microporous film 412. Thethicker or more uniform the adhesive coat layer 424 applied to themicroporous film 412, the more pores of the microporous film 412 will becovered or filled, thereby reducing the breathability of the microporousfilm 412. In addition, the breathability of the microporous film 412 canbe varied by varying a combination of any or all of the followingfactors: the thickness of the adhesive coat layer 424 (the amount ofadhesive or the percentage of coverage), the type of adhesive used inthe adhesive coat layer 424, and the type of adhesive application usedto apply the adhesive coat layer 424 to the microporous film 412.

The treated regions of the film extend at least 3 cm in the CD and MDand more desirably at least 5 cm×5 cm in the CD and MD. Further, thetreated regions of the surface can extend at least 10 cm in either theCD or MD direction. In a further aspect of the invention, the treatedregions desirably comprise from about 5% to about 90% of the area of thefilm. In a preferred embodiment of the present invention the treatedregions comprise a contiguous area comprising from about 5% to about 75%of the area of the overall film and more desirably comprise from about15% to about 60% of the area of the film. In a further embodiment, theregions can comprise a plurality of regions of intermediate and lowbreathability. The regions of low and intermediate breathabilitydesirably form a single contiguous area and which can, in one aspect, bedisposed about the central portion of the film. However, the treatedregions can comprise several non-contiguous regions and need not becentered on the breathable backing member 22.

In one embodiment of the present invention, the adhesive coat layer 424can be applied in a continuous pattern as seen in second regions 426 inFIG. 15a. The adhesive coat layer 424 can also be applied such that acontinuous second region 428 is disposed in the center of themicroporous film 412, creating a zoned breathability microporous film412, such as shown in FIG. 17a and 17 b, having highly breathableregions 426 adjacent the opposed edges of the film and a central secondregion 428 of reduced breathability therebetween. The reducedbreathability region 428 can extend continuously in the machinedirection of the microporous film. In a further aspect of the invention,the thickness (amount of adhesive or percentage of coverage) of theadhesive coat layer 424 can be varied in order to further modify thebreathability of the corresponding region of the film. Varying thethickness of the adhesive coat layer 424 results in varied levels ofbreathability extending in the machine direction.

Varying the thickness (including amount or percentage of coverage by theadhesive coat layer 424) is one method of controlling the breathabilityof the microporous film 412. Other methods include changing the methodof application of the adhesive coat layer 424. For example, a meltblownapplication of 3.2 gsm of adhesive onto the microporous film 412 hasvery little effect on the WVTR of the microporous film 412. However, theslot coating application of 3.2 gsm of adhesive onto the microporousfilm 412 has a marked effect on the WVTR of the microporous film 412.

In a further aspect of the invention, the adhesive coat layer 424 can beapplied in so as to create shaped regional breathability to themicroporous film. In reference to FIG. 19a and 19 b, the adhesive coatlayer 424 can be applied in different thicknesses (or types of adhesivesapplied or the type of adhesive application as discussed above) insecond regions 428 having different WVTRs. Thus, the microporous film412 is thereby creating having first region 426 and second region 428wherein first region 426 has a higher WVTR than second region 428. Thenarrow sections, second region 428, can be treated to have a higher orlower WVTR than wide sections, third region 429.

In a further aspect, the application of the adhesive coat layer 424 canbe discontinuous in the sense that the adhesive is applied in a brokenpattern as shown in FIGS. 18a, 18 b, and 20. The treatment of amicroporous film 412 as such create first region 426 and second region428 whereby first region 426 has greater breathability than secondregion 428. Further, second region 428 will be separated by portions offirst region 426 in the machine direction.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathability gradient across the CD of the film. Inreference to FIGS. 20 and 21, one such configuration can result in azoned breathable film 412 having a first region 426 of highbreathability, second region 428 of low breathability and third region429 of intermediate breathability.

As a further example, the adhesive coat layer 424 can be applied in ammaner to create a breathability gradient across the CD of the film 412.In reference to FIG. 21, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability, asecond region 428 of low breathability and a third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 is thicker (an increased amount or a higher percentageof coverage of the adhesive layer 424) than the adhesive coat layer 424in the CD of the microporous film 412, a breathability gradient havingregions of varied breathability across the CD of the microporous film412 is created as opposed to substantially distinct regions ofbreathability.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathability gradient across the CD of the film. Inreference to FIG. 21, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability,second region 428 of low breathability and third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 is of a different type of adhesive for use in theadhesive coat layer 424 applied in the third region 429, resulting in abreathability gradient. By varying the type of the adhesive coat layer424 in the CD of the microporous film 412 a breathability gradienthaving regions of varied breathability across the CD of the microporousfilm 412 is created as opposed to substantially distinct regions ofbreathability.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathability gradient across the CD of the film. inreference to FIG. 21, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability,second region 428 of low breathability and third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 under a different method of adhesive application ofthe adhesive coat layer 424 than used to apply the adhesive coat layer424 to the third region 429, resulting in a breathability gradient. Byvarying the type of adhesive application of the adhesive coat layer 424in the CD of the microporous film 412, a breathability gradient havingregions of varied breathability across the CD of the microporous film412 is created as opposed to substantially distinct regions ofbreathability.

The zoned treatment of the microporous film 412 acts to at leastpartially cover or fill the pores of the microporous film 412, therebyreducing the number or size of the pores in the treated regions therebyreducing the WVTR or breathability in those same regions. In referenceto FIGS. 16a and 16 b, the zone treated microporous film can have afirst substantially untreated region 426 which has a higher level ofbreathability than the second adhesively treated region 428 of themicroporous film. It is understood that the phrase “substantiallyuntreated region” refers herein to regions that may have undergone atreatment, however the treatment had little or no effect on the WVTR ofthe microporous film 412. The second region 428 will substantiallycorrespond to those areas of the microporous film to which an adhesivecoat layer 424 has been applied.

In a further aspect of the invention, the zoned breathabilitymicroporous film 412 can be joined with one or more additional layers.Alternatively, additional layers can be attached to the microporous filmprior to zone treating the film. Desirably the microporous film isattached to a pliable support layer capable of being laminated to thefilm such as, for example, a pliable fibrous, film and/or foam material.Exemplary fibrous layers include, but are not limited to, nonwoven webs,multilayer nonwoven laminates, scrims, woven fabrics, slit films and/orother like materials. Desirably the support fabric comprises one or morelayers of spunbonded and/or meltblown fiber webs including, but notlimited to, monocomponent spunbond fiber webs, multicomponent spunbondfiber webs, split fiber webs, multilayer nonwoven laminates, bondedcarded webs and the like. Generally, the composition of the fibrouslayer may be selected to achieve the desired properties, i.e. hand,aesthetics, tensile strength, cost, abrasion resistance, hookengagement, etc. Further, the fibrous layer can also be treated such as,for example, by embossing, hydroentangling, mechanically softening,printing or treated in another manner in order to achieve additionaldesired characteristics. In one embodiment the outer layer may compriseabout a 10 g/m² to about 68 g/m² web of spunbonded polyolefin fibers andeven more desirably a 10 g/m² to about 34 g/m² web of such fibers. Thefibrous layer can be attached or laminated to the microporous film byadhesive bonding, thermal bonding, ultrasonic bonding or other meansknown in the art. In one aspect of the invention the microporous filmand fibrous layer are bonding with an adhesive sprayed via a standardmeltblown die to either the nonwoven fabric and/or film. In a furtheraspect of the invention, the fibrous layer and microporous film can belaminated via thermal point bonding.

The microporous films of the present invention having controlledregional breathability can be used with a wide variety of products or ascomponents of products such as, for example, in personal care articles,infection control products, protective covers, garments and the like. Asa particular example, a microporous film similar to that shown in toFIGS. 16a, 16 b, 17 a, 17 b, 18 a, 18 b, 19 a, 19 b, and 20 can bereadily converted and incorporated within a breathable barrier of adiaper or incontinence garment whereby the regions of reducedbreathability of the microporous film extend along the central portionor crotch of the diaper and generally cover these regions of theabsorbent pad 58 likely to contain large amounts of aqueous liquid wastewhen the absorbent garments 20 are used. The regions more or lesscoextensive with the absorbent pad 58 are typically of lowerbreathability. By covering the absorbent pad 58 with areas of lowerbreathability, the chance of the outside of the absorbent garment 20feeling wet is minimized. (See FIGS. 22, 23, 24, and 25.).

FIG. 22 shows that the absorbent pad 58 need not cover the entire secondregion 428 and that the absorbent pad 58 may overlap onto a portion ofthe first region 426. Typically the portion of the absorbent pad 58which has the highest aqueous liquid loading is positioned over thesecond regions 428. FIG. 23 shows the zone treated microporous film 412of FIGS. 15a and 16 a including an absorbent pad 58 having smallerdimensions than the second region 428. FIGS. 18a and 20 show such amicroporous film 412. FIG. 25 shows an alternative embodiment as shownin FIG. 24 including a shaped backing member 22 and absorbent pad 58which have legcut outs typically included for improved fit and comfortof the garment 20. (See FIGS. 19a and 19 b.) However, the size and/orshape of the absorbent pad 58 may coincide with the size and/or shape ofthe second region 428.

The regions of higher breathability extend along the outer portions or“ears” of the garment to maximize comfort and skin dryness. In a furtherexample, the zoned breathability microporous films may be used insurgical gowns. It is believed that the regions of reducedbreathability, particularly areas where breathability has beensignificantly or almost completely reduced, may provide improved barrierproperties. For example, areas of reduced breathability are believed toprovide improved barrier properties to blood borne pathogens. Thus,surgical gowns can be fabricated employing the treated or lowbreathability regions within high risk areas, such as the forearms ofthe gown, and higher WVTR regions within lower risk areas. Themicroporous film can also be advantageously utilized in numerous otherapplications employing breathable barrier fabrics.

One embodiment of the present invention is a disposable, absorbentgarment 20 defining an initial expanded shape having longitudinal andtransverse axes, a front waist region 37, and a back waist region 39.The front waist region 37 and the back waist region 39 is generallyoppositely disposed on said longitudinal axis. A crotch region 35 isdisposed between the front waist region 37 and the back waist region 39.The breathable absorbent garment 20 comprises:

a breathable film backing member 22 comprising:

a first microporous region 426 having a WVTR of at least 800 g/m²/24hours;

a second region 428 having a WVTR less than the first region 426 whereinthe WVTR of the second region 428 is at least 15% less than the WVTR ofthe first region 426;

a aqueous liquid pervious body-side liner 40 joined to the backingmember 22 approximate a periphery of the joined body-side liner 40 andthe backing member 22;

a generally rectangular absorbent pad 58, having a front end edge 66, aback end edge 68 and a pair of opposing side end edges 62 and 64,positioned between the body-side liner 40 and the backing member 22 inboard of the periphery of the joined body-side liner 40 and the backingmember 22 and positioned generally in alignment with the second region428 of the backing member 22; and,

leg elastics 96 and 108 aligned along longitudinally extending marginsof the periphery, rendering the garment 20 elastically contractible andbody-conforming adjacent the crotch of a wearer.

Variations of the breathable absorbent garment of additional embodimentsmay include any combination of the following: The backing member 22 maybe a thermoplastic polymer. The thermoplastic polymer may be apolyolefin polymer. The second region 428 of the breathable film backingmember 22 may be adjacent the absorbent pad 58. The first region of thebreathable film backing member 22 may be adjacent the periphery of thejoined body-side liner 40 and the backing member 22. The first region426 of the breathable film backing member 22 may be disposed in thefront waist region 37 of the garment 20. The first region 426 of thebreathable film backing member 22 may be disposed in the back waistregion 39 of the garment 20 alone or in combination with disposition inthe front waist region 37. The second region of the backing member 22may have a minimum dimension of 3 cm by 3 cm, or more preferably, aminimum dimension of 5 cm by 5 cm. Typically, a minimum dimension is atleast as large as that of the region of the absorbent pad 58 likely toget wet during use.

The first region 426 may have a WVTR in excess of 2500 g/m²/24 hours andthe second region 428 may have a WVTR less than 1500 g/m²/24 hours andfurther wherein the second region 428 may comprise from about 5% toabout 75% of the area of the backing member 22. The second region 428may have a WVTR of at least about 25% less than the WVTR of the firstregion 426. The second region 428 may have a WVTR at least 50% less thanthe WVTR of the first region 426 and wherein each of said first andsecond regions 426 and 428 have a basis weight less than about 35 g/m².The second region 428 may have a WVTR at least about 75% less than theWVTR of the first region 426 and wherein each of the first and secondregions 426 and 428 may have a basis weight less than about 35 g/m². Thebreathable absorbent garment 20 may further comprise a third region 429,the third region 429 may have a WVTR intermediate to the WVTR of saidfirst region 426 and the WVTR of said second region 428 and wherein thesecond region 428 may comprise from about 5% to about 75% of the area ofsaid backing member 22. The breathable absorbent garment 20 may furthercomprise a third region 429, the third region 429 may have a WVTRintermediate to the WVTR of the first region 426 and the second region428 and wherein the third region 429 is contiguous with said first andsecond regions 426 and 428. The backing member 22 may comprise at leastabout 50% by weight of the thermoplastic polymer and a filler. Thesecond region 428 may extend at least 5 cm in the cross-machinedirection and may extend substantially continuously in the machinedirection of the backing member 22. The second region 428 may bepositioned symmetrically along the longitudinal axis of the garment 20.The backing member 22 may have a WVTR gradient.

In other embodiments, the present invention may be a disposable,breathable absorbent garment 20 defining an initial expanded shapehaving longitudinal and transverse axes, a front waist region 37, and aback waist region 39. The front waist region 37 and the back waistregion 39 is generally oppositely disposed on the longitudinal axis. Acrotch region 35 is disposed between the front waist region 37 and theback waist region 39. The breathable absorbent garment 20 comprises:

a film backing member 22 having regions of varied breathabilitycomprising:

a first microporous region 426 comprising a polyolefin polymer and afiller;

a second region 428 comprising a polyolefin polymer and a filler;

wherein the first and second regions 426 and 428 comprise a continuousbacking member 22 and wherein the WVTR of the second region 428 is lessthan the WVTR of the first region 426;

a aqueous liquid pervious body-side liner 40 joined to the backingmember 22 approximate a periphery of the joined body-side liner 40 andthe backing member 22;

a generally rectangular absorbent pad 58, having a front end edge 66, aback end edge 68 and a pair of opposing side end edges 62 and 64,positioned between the body-side liner 40 and the backing member 22 inboard of the periphery of said joined body-side liner 40 and the backingmember 22; and,

leg elastics 96 and 108 aligned along longitudinally extending marginsof the periphery, rendering the garment 20 elastically contractible andbody-conforming adjacent the crotch of a wearer.

Various embodiments of the present invention may include any of thefollowing: The second region 428 has a minimum dimension of 3 cm by 3cm. The second region 428 may comprise from about 5% to about 75% of thearea of the backing member 22. The first region 426 may have a WVTRbetween about 2000 g/m²/24 hours and about 5000 g/m²(24 hours and thesecond region 428 may have a WVTR less than about 1000 g/m²/24 hours.The second region 428 may have has a WVTR less than about 1500 g/m²/24hours and the first region 426 may have a WVTR in excess of about 2500g/m²/24 hours. The second region 428 may have a WVTR less than about 800g/m²/24 hours and comprises from about 5% to about 60% of the area ofthe backing member 22. The first and second regions 426 and 428 may eachhave substantially similar basis weights. The second region 428 has aWVTR at least about 50% less than the WVTR of the first region 426 andcomprises from about 5% to about 75% of the area of the backing member22. The first and second regions 426 and 428 may comprise at least about40% by weight of the filler. The polyolefin polymer of the first region426 and the polyolefin polymer of the second region 428 comprisepolyethylene. The polyolefin polymer of the first region 426 and thepolyolefin polymer of the second region 428 comprise polypropylene. Thebacking member 22 may further comprise a third region 429 having a WVTRless than the WVTR of the first region 426 and greater than the WVTR ofthe second region 428. The third region 429 may be contiguous with thesecond region 428 and further wherein the second region 428 and thethird region 429 together comprise from about 5% to about 75% of thearea of the backing member 22. The second region 428 may have adimension on the cross-machine direction less than the cross-machinedimension of the third region 429. The second region 428 and the thirdregion 429 may be contiguous and further wherein the second region 428may comprise from about 5% to about 60% of the area of the backingmember 22.

Test Methods

Hydrohead: A measure of the aqueous liquid barrier properties of afabric is the hydrohead test. The hydrohead test determines the heightof water or amount of water pressure (in millibars) that the fabric willsupport before aqueous liquid passes therethrough. A fabric with ahigher hydrohead reading indicates it has a greater barrier to aqueousliquid penetration than a fabric with a lower hydrohead. The hydroheadcan be performed according to Federal Test Standard 191A, Method 5514.The hydrohead data cited herein was obtained using a test similar to theaforesaid Federal Test Standard except modified as noted below. Thehydrohead was determined using a hydrostatic head tester available fromMarl Enterprises, Inc. of Concord, N.C. The specimen is subjected to astandardized water pressure, increased at a constant rate until thefirst sign of leakage appears on the surface of the fabric in threeseparate areas. (Leakage at the edge, adjacent clamps is ignored.).Unsupported fabrics, such as a thin film, are supported to preventpremature rupture of the specimen.

WVTR: The water vapor transmission rate (WVTR) for the sample materialswas calculated in accordance with ASTM Standard E96-80. Circular samplesmeasuring three inches in diameter were cut from each of the testmaterials and a control which was a piece of CELGARD™ 2500 film fromHoechst Celanese Corporation of Sommerville, N.J. CELGARD™ 2500 film isa microporous polypropylene film. Three samples were prepared for eachmaterial. The test dish was a number 60-1 Vapometer pan distributed byThwing-Albert Instrument Company of Philadelphia, Pa. One hundredmilliliters of water were poured into each Vapometer pan and individualsamples of the test materials and control material were placed acrossthe open tops of the individual pans. Screw-on flanges were tightened toform a seal along the edges of the pan, leaving the associated testmaterial or control material exposed to the ambient atmosphere over a6.5 centimeter diameter circle having an exposed area of approximately33.17 square centimeters. The pans were placed in a forced air oven at100° F. (32° C.) or 1 hour to equilibrate. The oven was a constanttemperature oven with external air circulating through it to preventwater vapor accumulation inside. A suitable forced air oven is, forexample, a Blue M Power-O-Matic 60 oven distributed Blue M. ElectricCompany of Blue Island, Ill. Upon completion of the equilibration, thepans were removed from the oven, weighed an immediately returned to theoven. After 24 hours, the pans were removed from the oven and weighedagain. The preliminary test water vapor transmission rate values werecalculated with Equation (I) below:

(I) Test WVTR=(grams weight loss over 24 hours)×315.5 g/m²/24 hours Therelative humidity within the oven was not specifically controlled.

Under the predetermined set conditions of 100° F. (32° C.) and ambientrelative humidity, the WVTR for the CELGARD™ 2500 control has beendefined to be 5000 grams per square meter for 24 hours. Accordingly, thecontrol sample was run with each test and the preliminary test valueswere corrected to set conditions using Equation (II) below:

(II) WVTR=(Test WVTR/control WVTR)×(5000 g/m²/24 hours)

Strip Tensile: The strip tensile test measures the peak and breakingloads and peak and break percent elongations of a fabric. This testmeasures the load (strength) in grams and elongation in percent. In thestrip tensile test, two clamps, each having two jaws with each jawhaving a facing in contact with the sample, hold the material in thesame plane, usually vertically, separated by 3 inches and move apart ata specified rate of extension. Values for strip tensile strength andstrip elongation are obtained using a sample size of 3 inches by 6inches, with a jaw facing size of 1 inch high by 3 inches wide, and aconstant rate of extension of 300 mm/min. The Sintech 2 tester,available from the Sintech Corporation, 1001 Sheldon Dr., Cary, N.C.27513, the Instron Model TM, available from the Instron Corporation,2500 Washington St., Canton, Mass. 02021, or a Thwing-Albert ModelINTELLECT II available from the Thwing-Albert Instrument Co., 10960Dutton Rd., Phila., Pa. 19154 may be used for this test. Results arereported as an average of three specimens and may be performed with thespecimen in the cross direction (CD) or the machine direction (MD).

EXAMPLE I

A cast extrusion film was made, comprising LLDPE (linear low densitypolyethylene; 0.918 g/cm³ from Dow Chemical Corp. in Midland, Mich.under the designation DOWLEX™ NAG 3310) and 48% by weight calciumcarbonate (available from English China Clay America, Inc. under thedesignation SUPERCOAT™) coated with stearic acid. The filled film wasthen heated and stretched 500% its original length using a machinedirection orientor unit to create a microporous film having a basisweight of approximately 14 g/m². The resulting breathable microporousfilm had a WVTR of 2358 g/m²/24 hours, a MD strip tensile of 6987 g anda CD strip tensile of 425 g. The breathable microporous film was woundon a supply roll and subsequently unwound and fed through a pair of niprolls at a speed of 50 feet/minute. Both rolls were steel rolls and theupper roll was patterned having configuration similar to that shown inFIGS. 1 and 3, having a raised region with a width of 8 inches thatextends about the center of the roll. The lower roll was a smooth anvilroll. The nip pressure and temperature of rolls were varied in order toobtain varied levels of regional breathability, the results of which areshown on Table I.

TABLE I Anvil #1 Anvil #2 Temp. Temp. Nip Pressure WVTR Strip TensileTrial (Actual) (Actual) PSIG PLI g/m²/day MD CD 1 75 75 15 88 2210 6399459 2 75 75 30 145 1660 6031 441 3 75 75 45 215 1399 6208 442 4 75 75 60297 1426 6054 436 5 105 105 15 88 1914 6453 465 6 105 105 30 145 15485991 452 7 105 105 45 215 1243 6347 450 8 105 105 60 297 1033 5331 449 9123 123 15 88 1657 6638 461 10 123 123 30 145 1385 6329 467 11 123 12345 215 1148 5961 458 12 123 123 60 297 1012 5172 461 13 150 150 15 881471 6613 470 14 150 150 30 145 1192 6232 477 15 150 150 45 215 10676336 483 16 150 150 60 297 1542 6523 441 17 170 170 15 88 1878 6938 44518 170 170 30 145 1234 6626 461 19 170 170 45 215 1174 6794 471 20 170170 60 297 851 6481 474 21 195 195 15 88 970 6917 496 22 195 195 30 145583 6800 503 23 195 195 45 215 538 6568 601 24 195 195 60 297 219 6683604 25 220 220 15 88 185 6947 610 26 220 220 30 145 95 7308 737 27 220220 45 215 59 6828 735 28 220 220 60 297 62 6893 740

EXAMPLE II

The stretched-filled microporous film described in Example I waslaminated to a nonwoven web. The microporous film was sprayed with 3g/m² of adhesive (amorphous polyalphaolefin adhesive available fromHuntsman Polymer Corporation under the trade name RT 2730) andimmediately thereafter a 17 g/m² web of polypropylene spun bond fiberswas juxtaposed with and pressed against the microporous film by a pairof smooth nip rolls. The laminate was subsequently zone treated throughthe nip rolls described in Example I at a rate of 50 feet/minute. Theresulting laminates are described in Table II. The film laminate, priorto zone treatment, had a peel strength of 860 g, a hydrohead of 162 mbarand a WVTR of 2457 g/m²/24 hours.

TABLE II Anvil #1 Anvil #2 Temp. Temp. Nip Pressure WVTR Hydrohead Trial(Actual) (Actual) PSIG PLI g/m²/day Mbar 1  75  75 30 145 2138 144 2  75 75 60 297 1970 116 3 130 130 30 145 1979 111 4 130 130 60 297 1521 1115 220 220 30 145  430  82 6 220 220 60 297  347  52

EXAMPLE III

A microporous polyethylene film was laminated to a non-woven fabric toform an outer cover. Adhesive was then added to the film side of theouter cover laminate (which faces the wearer's body when incorporated inan absorbent garment) to create two breathable zones. Adhesive appliedthrough a meltblown application at a level of 3.2 gsm was appliedcontinuously, the full length of the article. A second adhesive head wasused to apply adhesive, generally the length and width of the absorbentcore, through a slot die at the same and higher add-on rates. The firstadhesive system had minimal effect on the film WVTR while the secondsubstantially reduced it. The adhesive used has designation 34-5610 fromNational Starch and Chemical Company in Bridgewater, N.J.

WVTR After WVTR After WVTR After Meltblown Slot Coated Slot CoatedLaminate Adhesive Adhesive Adhesive Applic. WVTR Applic. 3.2 gsm Applic.3.2 gsm 6.4 gsm 4,136 3,899 3,087 2,414 4,232 3,933 3,028 2,332 (WVTRunits g/m2/24 hours)

EXAMPLE IV

Referencing the WVTR data in Example III, FIG. 26 shows a breathablefilm with a meltblown adhesive coverage of about 8%. This resulted inthe WVTR dropping from about 4200 to about 3900. FIG. 27 shows abreathable film with a coat layer coverage of about 24% resulting inabout a 1000 drop in WVTR. FIG. 28 shows a 70% coat layer coverage whichresulted in a WVTR drop of about 1800.

EXAMPLE V

It has been found that slot coating applied to a non-woven web has lesseffect on the laminate WVTR than applying to the film. A slot coater,therefore could be used to maintain high WVTR in the desired productregions if slot coating is applied to a non-woven like fabric ratherthan onto the film.

An equal amount of construction adhesive (34-5610 from National Starchand Chemical Company in Bridgewater, N.J.) was applied via slot coatingonto both a non-woven fabric (0.75 osy, sheath/core, 50/50 polypropylenepolyethylene spunbond) and a microporous polyethylene film with a WVTRof approximately4,270. The examples show the smaller reduction in WVTRwhen the non-woven was slot coated compared to when the film wasslot-coated.

Laminate WVTR WVTR When Film When Slot Coated Laminate Slot Coated WVTRonto Non-woven WVTR onto Film 4,270 4,080 4,080 3,500

EXAMPLE VI

It has been found that neither a meltblown (also referred to as MB) norswirl adhesive application lower the WVTR of the microporous filmsignificantly at adhesive levels up to 3.2 gsm of 34-5610 adhesive.

Description WVTR Film 4,266 3.2 gsm MB on nonwoven 4,178 1.6 gsm MB onfilm 4,317 3.2 gsm Swirl on film 4,063 1.0 gsm Swirl on film 4,486

EXAMPLE VII

This example demonstrates that high WVTR values can result incondensation of wter vapor on the outer surface of an absorbent garment.This is perceived as leakage by many consumers.

Panelists evaluated the materials in a blind comparison using thefollowing test method. Before evaluation, all samples were loaded with240 mls of body temperature saline, and placed on a heating pad alsowarmed to body temperature for two hours, Each diaper was placed insidea black box for a blind evaluation. All participants evaluated eachmaterial four times as presented to them in a randomly ordered sequence.Each material by feeling it was evaluated inpendently. Each of the twostudies included three codes. In each study panelists evaluated a totalof twelve diapers (3 codes×4 repeats=12 diapers) with a fifteen minutebreak after evaluating six diapers to help reduce hand fatigue.

WVTR of Front Moisture Back Moisture Product Outer Cover Rating Rating A1,650 15.9 22.1 B 2,715 18.8 24.1 C 4,125 20.9 26.3 D 0 12 18 ProductsA, B, C, and D were commercially available diapers in which the outercovers were replaced with over covers having the stated WVTR.

EXAMPLE VIII

This example demonstrates that high WVTR levels in nonabsorbent areas ofa disposable garment increase wearer comfort. The disposable garmentstested were commercially available DEPENDS Undergarments. The test wasconducted on a KES-F7 Thermo-Lobo IIB Type equipment available fromKato-Tech Co., LTD., in Kyoto, Japan. The test method is described inthe operating manual for the equipment. Outer covers of differingbreathability were tested.

The ability of moisture and heat to permeate through fabric is asignificant factor in determining how comfortable a garment will be.Heat can be transferred through a fabric in two ways: dry heat transferand/or moisture-assisted heat transfer. From the dry and wet heattransfer rate measurements, the permeability index (Im), can becalculated. The KES Thermo-labo test measures the dry and wet heattransfer rates of a material using a guarded or sweating hot plate. Italso measures how warm or cool a material feels to the touch and thethermal conductivity of materials.

The characteristic values shown from the KES Thermo-labo test aredescribed below.

Wet Heat Transfer represents the amount of heat that is transferred fromthe skin through the fabric to the outside environment with theassistance of moisture. The larger the wet heat transfer value, the moreheat will be lost or transferred through the fabric with the assistanceof moisture. This test is appropriate for the measurement of heattransfer in most situations where the wearer would perspire.

Im or Permeability Index is the ratio of the thermal and evaporativeresistance of the fabric to the ratio of thermal and evaporativeresistance of air. As the value approaches 1, the less resistant or moreair-like the fabric is. For example, a lightweight, loosely woven fabricwould have a larger Im value than Tyvek. (Differences as small as 0.01can be perceived.)

Non-breathable 1,200 WVTR 2,500 WVTR 3.5 osy non-micro- microporousmicroporous woven porous film film film cotton Wet Heat 7.72 8.87 11.9418.4 Transfer (Watts/m²) Im or 0.18 0.23 0.39 0.59 Permeability Index

EXAMPLE IX

This example demonstrates that high WVTR levels in certain areas of adisposable garment increase wearer skin wellness by reducing skinocclusion and excessive hydration of the skin.

Undergarments that were modifications of commercially available DEPEND®Undergarments, were tested with 20 panelists. The modifications includedshortening the absorbent pad from 21 inches to 19 inches (centered onthe outer cover) and incorporating new outer covers with the statedWVTRs. The outer covers consisted of a film (either non-porous ormicroporous) and a nonwoven laminated to the film.

Skin conductance measurements were taken on the panelist's lower back ina region where the garment's body-side liner and outer cover covered theskin (not in a region where the absorbent pad was present).

The skin conductance readings were taken with a Skicon 200 instrumentsuch as that available from ACA DERM of Mento Park, Calif. Panelistswere given a short sleeve disposable lab coat, made of polypropylenespunbond, cotton sweatpants, and a pair of cotton underwear to wearduring the test period. Panelists were then allowed to acclimate to theenvironment which was controlled to approximately 72° F./43% R. H. for10-15 minutes. After acclimation, the panelists lay on their stomachs,their clothing over their lower back was peeled down, and a Baselineskin conductance reading was taken using the Skicon.

Subsequently, the panelists were given an undergarment to don, undertheir underwear and sweatpants. The total wear time of the undergarmentwas 1.5 hours. During the first ten minutes of wear time, the panelistsparticipated in a moderate exercise of their choice (such as walking,threadmill, stationary bike, aerobic activity). The next twenty minutes,the panelists rested. They exercised the next ten minutes (30-40 minutesinto wear time), rested the next 20 minutes (40-60 minutes into weartime), exercised the next ten minutes (60-70 minutes into wear time),and finally rested the last twenty minutes of the 1.5 hour undergarmentweartime.

After the 1.5 hour wear time, a post-wear skin conductance reading wastaken in the same manner and region as the baseline reading.

The change in skin conductance, from the baseline to post wear regions,represents the change in skin hydration during that period. The datashows that the non-breathable product resulted in a much greaterincrease in skin hydration than the breathable products. Such increasesover time lead to wearer discomfort and reduced skin wellness.

Baseline Skin Post wear Skin Change in Skin Sur- Surface Moist- SurfaceMoist- face Moisture Read- ure Reading ure Reading ing after Wear TimeNon breathable 220 1,187 967 non-microporous film 2,500 WVTR 222 376 154microporous film 3,700 WVTR 239 364 125 microporous film

While various patents and other reference materials have beenincorporated herein by reference, to the extent there is anyinconsistency between incorporated material and that of the writtenspecification, the written specification shall control. In addition,while the invention has been described in detail with respect tospecific embodiments thereof, it will be apparent to those skilled inthe art that various alterations, modifications and other changes may bemade to the invention without departing from the spirit and scope of thepresent invention. It is therefore intended that the claims cover allsuch modifications, alterations and other changes encompassed by theappended claims.

We claim:
 1. A disposable, breathable absorbent garment defining aninitial expanded shape having longitudinal and transverse axes, a frontwaist region, a back waist region, said front waist region and said backwaist region being generally oppositely disposed on said longitudinalaxis and a crotch region disposed between said front waist region andsaid back waist region and comprising: a breathable film backing membercomprising: a first microporous region having a WVTR of at least 800g/m²/24 hours; a second region having a WVTR less than said first regionwherein the WVTR of said second region is at least 15% less than saidWVTR of said first region; a aqueous liquid pervious body-side linerjoined to said backing member approximate a periphery of said joinedbody-side liner and said backing member; a generally rectangularabsorbent pad, having a front end edge, a back end edge and a pair ofopposing side end edges, positioned between said body-side liner andsaid backing member in board of the periphery of said joined body-sideliner and backing member; and, leg elastics aligned along longitudinallyextending margins of said periphery, rendering said garment elasticallycontractible and body-conforming adjacent the crotch of a wearer.
 2. Thegarment of claim 1, wherein said backing member is a thermoplasticpolymer.
 3. The garment of claim 1, wherein said second region of saidbreathable film backing member is adjacent said absorbent pad.
 4. Thegarment of claim 3, wherein said backing member is a thermoplasticpolymer.
 5. The garment of claim 1, wherein said first region of saidbreathable film backing member is disposed in said front waist region ofsaid garment.
 6. The garment of claim 5, wherein said backing member isa thermoplastic polymer.
 7. The garment of claim 1, wherein said firstregion of said breathable film backing member is disposed in said backwaist region of said garment.
 8. The garment of claim 7, wherein saidbacking member is a thermoplastic polymer.
 9. The garment of claim 1,wherein said first region of said breathable film backing member isdisposed in said front waist region and said back waist region of saidgarment.
 10. The garment of claim 3, wherein said backing member is athermoplastic polymer.
 11. The garment of claims 2, wherein said secondregion of said backing member has a minimum dimension of 3 cm by 3 cm.12. The garment of claims 3, wherein said second region of said backingmember has a minimum dimension of 5 cm by 5 cm.
 13. The garment of claim2, wherein said thermoplastic polymer is a polyolefin polymer.
 14. Thegarment of claim 4, wherein said thermoplastic polymer is a polyolefinpolymer.
 15. The garment of claim 1, wherein said first region has aWVTR in excess of 2500 g/m²/24 hours and said second region has a WVTRless than 1500 g/m²/24 hours and further wherein said second regioncomprises from about 5% to about 75% of the area of said backing member.16. The garment of claim 2, wherein said second region has a WVTR atleast about 25% less than the WVTR of said first region and wherein eachof said first and second regions have a basis weight less than about 35g/m².
 17. The garment of claim 16, wherein said first region has athickness less than about 95% of the thickness of said second region andsaid second region comprises from about 5% to about 75% of the area ofsaid backing member.
 18. The garment of claim 2, wherein said secondregion has a WVTR at least 50% less than the WVTR of said first regionand wherein each of said first and second regions have a basis weightless than about 35 g/m².
 19. The garment of claim 18, wherein said firstregion is less than 90% of the thickness of said second region andwherein the basis weight of said first and second regions aresubstantially similar.
 20. The garment of claim 2, wherein said secondregion has a WVTR at least about 75% less than the WVTR of said firstregion and wherein each of said first and second regions have a basisweight less than about 35 g/m².
 21. The garment of claim 1, furthercomprising a third region, said third region having a WVTR intermediateto the WVTR of said first region and the WVTR of said second region andwherein said second region comprises from about 5% to about 75% of thearea of said backing member.
 22. The garment of claim 18, furthercomprising a third region, said third region having a WVTR and thicknessintermediate to the WVTR and thickness of said first region and saidsecond region and wherein said third region is contiguous with saidfirst and second regions.
 23. The garment of claim 2, wherein saidbacking member comprises at least about 50% by weight of saidthermoplastic polymer and a filler.
 24. The garment of claim 1, whereinsaid second region extends at least 5 cm in the cross-machine directionand extends substantially continuously in the machine direction of saidbacking member.
 25. The garment of claim 1, wherein said second regionis positioned symmetrically along the longitudinal axis of said garment.26. The garment of claim 25, wherein said backing member has a WVTRgradient.
 27. A disposable, breathable absorbent garment defining aninitial expanded shape having longitudinal and transverse axes, a frontwaist region, a back waist region, said front waist region and said backwaist region being generally oppositely disposed on said longitudinalaxis and a crotch region disposed between said front waist region andsaid back waist region and comprising: a film backing member havingregions of varied breathability comprising: a first microporous regioncomprising a polyolefin polymer and a filler; a second region comprisinga polyolefin polymer and a filler; wherein said first and second regionscomprise a continuous backing member and wherein the WVTR of said secondregion is less than the WVTR of said first region and the thickness ofsaid first region is less than the thickness of said second region; aaqueous liquid pervious body-side liner joined to said backing memberapproximate a periphery of said joined body-side liner and said backingmember; a generally rectangular absorbent pad, having a front end edge,a back end edge and a pair of opposing side end edges, positionedbetween said body-side liner and said backing member in board of theperiphery of said joined body-side liner and backing member; and, legelastics aligned along longitudinally extending margins of saidperiphery, rendering said garment elastically contractible andbody-conforming adjacent the crotch of a wearer.
 28. The garment ofclaim 27, wherein said first and second regions have a basis weight lessthan about 35 g/m² and said second region has a minimum dimension of 3cm by 3 cm.
 29. The garment of claim 28, wherein said second regioncomprises from about 5% to about 75% of the area of the backing member.30. The garment of claim 29, wherein said first region has a WVTRbetween about 2000 g/m²/24 hours and about 5000 g/m²/24 hours and saidsecond region has a WVTR less than about 1000 g/m²/24 hours.
 31. Thegarment of claim 29, wherein said second region has a WVTR less thanabout 1500 g/m²/24 hours and said first region has a WVTR in excess ofabout 2500 g/m²/ 24 hours.
 32. The garment of claim 30, wherein saidsecond region has a WVTR less than about 300 g/m²/24 hours and comprisesfrom about 5% to about 60% of the area of said backing member.
 33. Thegarment of claim 28, wherein said first and second regions each havesubstantially similar basis weights.
 34. The garment of claim 27,wherein said second region has a WVTR at least about 50% less than theWVTR of said first region and comprises from about 5% to about 75% ofthe area of said backing member.
 35. The garment of claim 29, whereinsaid first and second regions comprise at least about 40% by weight offiller.
 36. The garment of claim 35, wherein said polyolefin polymer ofsaid first region and said polyolefin polymer of said second regioncomprise polyethylene.
 37. The garment of claim 35, wherein saidpolyolefin polymer of said first region and said polyolefin polymer ofsaid second region comprise polypropylene.
 38. The garment of claim 28,wherein said backing member further comprises a third region having aWVTR less than the WVTR of said first region and greater than the WVTRof said second region.
 39. The garment of claim 38, wherein said thirdregion is contiguous with said second region and further wherein saidsecond and third regions together comprise from about 5% to about 75% ofthe area of said backing member.
 40. The garment of claim 38, whereinsaid second region has a dimension on the cross-machine direction lessthan the cross-machine dimension of said third region.
 41. The garmentof claim 40, wherein said second and third regions are contiguous andfurther wherein aid second region comprises from about 5% to about 60%of the area of said backing member.